The labor costs in electronic manufacturing remain high?
The labor costs in electronic manufacturing remain high?--Zhongkeyuan CPET fully automatic aging testing production line, achieving unmanned manufacturing to reduce costs and improve efficiency
Difficulty in recruiting workers, high labor costs, frequent human errors, and skyrocketing costs for night shifts - in the current electronics manufacturing industry, the aging test process has become a major area where labor costs are high.
The traditional aging test production line is highly dependent on manual loading and unloading, on-site monitoring and inspection, and paper-based record-keeping of data. It not only requires a large number of front-line workers but also faces a series of problems such as large errors in manual testing, long production line model change cycles, inability to trace production data, and insufficient night-shift production capacity, which continuously reduces the profit margin of the factory. How to break free from the constraints of human labor and achieve an all-robotic, lean upgrade of the testing section?
At CPET, Zhongyuan has been deeply engaged in the field of power electronics testing for over a decade. Relying on its self-developed core technologies, it has built a fully automatic intelligent aging testing production line. With its three core capabilities of modularization, intelligence, and digitalization, it completely replaces the manual testing process, helping electronic manufacturing enterprises reduce labor costs, increase production capacity, control quality, and solve the employment pain points in intelligent manufacturing in a one-stop manner.
I. Modular Design: Block-like flexible layout, suitable for flexible production of various categoriesAbandoning the drawbacks of traditional integrated fixed production lines, such as difficult transformation, poor adaptability and high investment costs, the CPET production line of Zhongyuanyuan adopts a modular architecture. The core components including the power unit, load unit, liquid cooling temperature control unit, automatic loading and unloading unit, and energy feedback unit are independently separated and can be freely combined and assembled.
Rapid Model Changeover: The production line can be reconfigured in just 2 hours. It can easily meet the testing requirements of over 90% of electronic products such as power supplies, new energy storage, vehicle electronics, inverters, adapters, etc. It perfectly suits the current small-batch, multiple-batch order production mode.
Flexible deployment: According to the size of the workshop site, it can freely switch between single-machine testing, multi-machine parallel operation, and whole-line linkage modes. Old workshops can be quickly implemented without the need for large-scale infrastructure renovations.
Phased investment: Supports the modular stacking of processing units as needed. Enterprises can expand capacity step by step according to the production capacity growth schedule, thereby reducing the pressure of initial equipment investment.
Energy conservation and cost reduction: Equipped with a high-efficiency energy feedback module, the energy feedback rate reaches up to 80%. The waste heat electrical energy is reversed and connected to the grid for use, reducing the production and operation costs in two ways.
II. Full-process Intelligence: Completely eliminating reliance on human interventionThe entire system is equipped with industrial-grade intelligent PLC control systems, enabling a complete automated closed-loop process from product loading, automatic aging, condition monitoring, defective product sorting to unloading. This ensures that the testing process is fully automated without any human intervention.
There is no need for manual handling of products, no need for dedicated personnel to be on-site, and no need for night shift personnel to keep watch. The system can dynamically adaptively adjust the test power and temperature. The test accuracy error is less than 0.5%, which is far superior to the standards of manual operation. At the same time, it is equipped with multiple safety protection mechanisms such as overvoltage, overcurrent, overtemperature, and smoke detection. Faults will be automatically alarmed, the machine will be stopped urgently, and the fault location will be accurately determined, eliminating the potential safety hazards caused by human negligence during on-site monitoring.
Relying on the all-weather unmanned operation capability, it breaks the limitation of manual working hours, and the overall production capacity of the production line has increased by more than 50%. This solves the industry's stubborn problems such as difficulty in recruiting workers, difficulty in retaining workers, and the continuous increase in labor costs from the source.
III. Full-Chain Digitalization: Achieve comprehensive data visibility, and build the data foundation for intelligent manufacturingIn response to the problems of chaotic manual data recording, prone errors in ledgers, inability to trace quality issues, and lack of management basis in traditional methods, Zhongyuanyuan CPET has developed an exclusive digital monitoring platform, creating a digital control system for the entire testing process.
The system collects core production parameters such as voltage, current, temperature, and aging duration in a comprehensive manner. It automatically generates visualized production capacity and quality reports, enabling the early detection of product defects and facilitating the transition from post-quality inspection to pre-risk prevention. The production line can seamlessly connect with the factory's MES production management system. Remote real-time monitoring of the production line is available via mobile phones, computers, and tablets, allowing managers to monitor the overall operation status without having to physically visit the workshop.
All test data are fully retained in the cloud and cannot be tampered with. A single click allows for the export of compliant quality inspection reports, enabling easy handling of customer factory audits, quality traceability, and research and development data analysis requirements, thereby facilitating the factory's digital manufacturing upgrade.
Actual benefits achievedMultiple leading electronic and energy storage factories have provided real feedback:The manpower in the testing section has been reduced by over 80%, the rate of human errors has been eliminated, and the product defect rate has significantly decreased;The modular and flexible production lines can adapt to various orders, and the reuse rate of the production lines has greatly increased;The digital data closed-loop management has made the production control more transparent, and the upgrade of factory intelligentization has no threshold.
The human resource advantage is fading, and the trend of unmanned manufacturing has become inevitable.The CPET Kexinyuan fully automatic aging test production line adopts a modular design to adapt to various orders, replaces manual operation with intelligent technology, and empowers lean management through digitalization. This enables the aging test section to truly achieve: reduced personnel, zero errors, high production capacity, traceability, and low costs.
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