This project involves a client who is a leading refrigerator compressor manufacturer in China, with an annual production capacity of several million units. Facing fierce market competition, the client aimed to introduce a full-line automated welding system to achieve end-to-end automation across over 10 processes, from lower shell foot welding to protective cover welding.
The goal was to significantly reduce reliance on manual labor, improve welding quality, and enhance production efficiency. After multiple rounds of technical evaluation and supplier screening, our company was ultimately selected as the provider of the non-standard automation solution to jointly advance this automated welding project.
I. User Background and Requirements
1. Brief User Background
The client is a leading domestic compressor manufacturer, with products widely used in household refrigerators and freezers. Driven by growing market demand and national intelligent manufacturing policies, the company had been gradually upgrading automation in its existing production lines. However, the welding segment still relied heavily on manual operations, becoming a key bottleneck hindering overall efficiency.
2. Overview of User Requirements
①Challenges Faced by the User
- High Labor Costs: Traditional welding processes depended on skilled technicians, who had high turnover rates and long training cycles.
- Inconsistent Welding Quality: Manual welding was susceptible to factors like mood and fatigue, leading to fluctuations in product defect rates.
- Low Production Efficiency: Single-shift output was limited by manpower, making it difficult to meet demand during peak order periods.
- High Safety Risks: High-temperature welding operations posed safety hazards, with frequent incidents of work-related injuries.
②User Expectations for Non-Standard Automation
The client hoped we would tailor a highly integrated, flexible, and intelligent full-line automated welding system, with specific requirements as follows:
- Functional Requirements: Cover 9 core processes including lower shell foot welding, spring seat welding, process tube welding, suction pipe welding, discharge pipe welding, process tube bending, bracket bending & welding, terminal welding, and protective cover welding.
- Efficiency Target: Achieve a single-line output of ≥450 compressor housings per hour.
- Quality Standard: Achieve a welding pass rate of ≥99.5%, with uniform and aesthetically pleasing weld seams complying with the national standard GB/T 985.
- Compatibility Requirement: Support quick changeover for 3 or more product models, accommodating future product upgrades.
- User-Friendly Interface: Equipped with a visual operation interface and fault diagnosis system for ease of daily maintenance and management.
II. Development of a Customized Solution
1. Customized Design Process
Our project team conducted in-depth on-site research at the client's facility, thoroughly investigating the existing production process flow and layout. Based on the client's actual pain points, we adopted a modular design concept and advanced the following work in stages:
- Process Route Optimization: Re-sequenced the order and logical relationships of various welding processes to eliminate redundant actions.
- Robot Path Planning: Utilized six-axis welding robots paired with laser vision positioning systems to ensure welding accuracy and stability.
- Fixture System Development: Designed dedicated quick-change fixtures for different welding positions to achieve multi-model compatibility.
- Control System Integration: Established a PLC + HMI central control platform for whole-line coordination and data acquisition.
- Safety Protection Mechanisms: Implemented multiple safety measures including light curtain protection zones, emergency stop buttons, and gas leak alarms.
2. Customized Outcome
The final delivered full-line automated welding system consisted of 9 independent workstations, covering multiple functional modules such as welding, bending, and inspection. All core components utilized internationally renowned brands (e.g., Yaskawa motors, Keyence sensors, Panasonic servo systems) to ensure system stability and durability. The entire line features:
- High Automation: Unmanned operation for all processes except loading/unloading.
- Flexible Production: Quick changeover between different compressor models via program switching.
- Intelligent Monitoring: Built-in MES interface for real-time upload of production data to the client's ERP system.
- Green & Energy-Saving Design: Utilizes energy-saving welding power sources and circulating cooling systems to reduce energy consumption and operating costs.
III. Project Delivery Process
1. Factory Acceptance Demonstration
Upon project completion, the client organized a joint acceptance involving representatives from technical, production, and quality departments. System performance was comprehensively evaluated through simulated continuous operation tests, welded sample inspections, and operation interface demonstrations. The client highly praised our performance in welding precision, cycle time control, and equipment stability, and signed the acceptance confirmation on the spot.
2. On-site Debugging and Delivery Training
After the equipment arrived at the client's site, our company dispatched a team of professional engineers for on-site installation and debugging, fully supporting the client in the following tasks:
- Equipment Installation & Commissioning: Completed full-line assembly and electrical connection in 3 days.
- Process Parameter Optimization: Adjusted welding current, voltage, and other parameters based on the client's raw material characteristics.
- Employee Operation Training: Conducted a 2-day intensive training covering equipment operation, daily checks, and basic troubleshooting.
- Trial Run & Handover: Officially commenced trial operation, running continuously for 72 hours without issues, and ultimately passed the client's final review smoothly.
The entire project, from contract signing to official operation, took only 65 days, approximately 20% shorter than the industry average.
IV. Project Results Showcase
1. Production Efficiency Improvement Data (Compared to Traditional)
| Metric | Traditional Manual Line | Automated Line | Improvement |
| Single-Shift Output | ~2,000 units/shift | ~3,600 units/shift | +80% |
| Cycle Time | 12 seconds/unit | 8 seconds/unit | -40% |
| Manpower per Line | 12 persons/line | 2 persons/line | -83% |
2. Welding Quality Improvement Data
| Metric | Traditional Manual | Automated System | Improvement |
| Welding Pass Rate | 96.2% | 99.7% | +3.5 percentage points |
| Weld Consistency | ±1.2mm | ±0.3mm | Improved by 75% |
| Rework Rate | 3.8% | 0.3% | Reduced by 92% |
3. Cost-Benefit Analysis
- Direct Labor Savings: Approximately 1.5 million RMB/year in labor costs saved per production line.
- Quality Cost Reduction: Over 800,000 RMB/year reduction in rework and scrap losses caused by welding defects.
- Return on Investment Period: Total equipment investment was around 5 million RMB, with an expected payback period of approximately 14 months.
- Comprehensive Benefits: Overall operational costs decreased by over 25%, significantly enhancing the client's market responsiveness.
V. User Evaluation
1. User Feedback
"The successful implementation of this full-line automated welding project has not only helped us achieve our goals of cost reduction and efficiency improvement but has also elevated our intelligent manufacturing level within the industry. The solution provided by your company closely aligns with our actual needs. The equipment runs stably with excellent welding quality, and your service response is prompt and reliable. You are a trustworthy partner."
- Production Department Head, Compressor Manufacturer
2. Outlook for Long-term Cooperation & Recommendation
The client expressed its intention to deepen the cooperative relationship with our company, planning to upgrade and automate all its production lines within the next two years. Furthermore, the client is actively recommending our automation solutions to other manufacturers in the industry, helping more manufacturing enterprises advance on their path to intelligent transformation.
Conclusion
As the wave of Industry 4.0 continues to advance, automation, digitalization, and intelligence have become inevitable trends in manufacturing development.
The successful implementation of this refrigerator compressor full-line automated welding project has not only delivered significant economic and social benefits to the client but has also provided our company with valuable experience in the field of non-standard automation.
In the future, we will continue to deepen our expertise in intelligent manufacturing, providing efficient, stable, and sustainable automation solutions for more enterprises, contributing to the transformation of 'Made in China' into 'Intelligently Made in China'!
