Yawei Corporation's application of mature intelligent production line solutions in the elevator industry.

One.Introduction

Yawei Corporation has built a wide-ranging customer base within the elevator industry. Our product offerings for customers have evolved from standalone CNC sheet metal equipment towards more intelligent and flexible units, and ultimately, high-end automated production line products. With a dedicated sales team, we have deep-rooted ourselves in the foundation of our customers' products, listened to their production mode requirements, and relied on our company's robust technical support to provide tailored designs and system integration. We offer comprehensive and mature overall solutions to our customers. This has reduced manual labor, improved efficiency, enhanced our reputation, and won us loyal customers.

In the elevator industry, the primary sheet metal products include car walls, door panels, and others. The typical process involves stamping, cutting, bending and forming, and door panel techniques. Flexible unit products are standard stamping and folding products. Depending on the specific product requirements, they are typically categorized as either one-stamp, one-fold or one-stamp, multiple-fold. Door panel techniques, on the other hand, are typically customized based on varying door panel requirements and require an in-depth understanding of the specific needs.

The door panel techniques are typically categorized based on the type of door panel:

1. Stainless steel door panels with four edges and eight folds, reinforced ribs with adhesive assembly, compression, welding, or riveting at the four corners and reinforced rib connections.
2. Carbon steel door panels with four edges and eight folds, reinforced ribs with spot welding assembly, welding, or riveting at the four corners and reinforced rib connections.
3. Stainless steel door panels with four edges and two folds with end caps, reinforced ribs with adhesive assembly, compression, end cap adhesive assembly, and welding at the four corners.
4. Carbon steel door panels with four edges and two folds with end caps, reinforced ribs with spot welding, end cap spot welding, and welding at the four corners.
5. Some car wall door panels may have four sides with ten folds or four sides with six folds. Reinforced ribs can be arranged both horizontally and vertically, among other variations.

Two.Solution

To meet the capacity upgrade needs of industry clients, improve labor efficiency, and enhance working conditions, one of the solutions provided by Yawei Design for the production of elevator door panels is as follows: It includes processes from material storage, automatic feeding, stamping, automatic bending, automatic gluing, robotic laser welding, automatic packaging, and box stacking.

We have extensive experience in designing production solutions for door panels, so we are fully capable of customizing solutions based on customer requirements. For example, in one case, a customer in the industry had the need to bring two types of door panels online, both made from different materials. They needed these two production lines to converge in the future and wanted to leave room for optimization and expansion. The customer faced tight production schedules and limited space in their facility. When the new intelligent production line was installed, it had to be put into operation immediately, causing the two manual lines to stop working and free up space.

This posed new challenges in terms of meeting the customer's customization needs, process requirements, production speed demands, and the performance requirements of the intelligent door panel production line. To ensure uninterrupted operation and maximize efficiency, every step in the process had to be error-free. We meticulously analyzed the customer's workpiece, considering each assembly process's technical requirements and characteristics. We translated the customer's requirements on-site into solutions, proposed optimization suggestions collaboratively, and continuously improved the plan in a timely manner.

The entire production line is capable of processing a diverse range of intelligent door panels, including two different types, multiple sizes, and two different materials. It covers a comprehensive set of processes, including material storage, feeding, stamping, forming, flipping, gluing, compression, heating, welding, packaging, and stacking. The system is designed to provide a holistic solution and allows for future expansion and integration with production management systems, ensuring flexibility and adaptability to changing production requirements.

1、Material Storage and Stamping Forming.

To achieve the goal of producing both types of door panels while managing limited space and material storage, two automated production lines were designed to share a common material storage area. The material storage facility was specially designed to prevent material misalignment, and new positioning benchmarks were established. Raw materials are transported from both sides and directed to the loading area of the stamping machines.

The stamping and bending automated processing system utilizes robots to achieve full automation in the stamping process. It handles automatic loading and unloading on the press, punching, automatic shaping, and automatic bending. Through optimization of programming and pathways, this system maximizes processing efficiency, eliminating the need for manual labor and ensuring a consistent improvement in product quality.

2、Door Panel Automatic Production Line.

For processing two-layer doors with slightly different process paths, integrating the commonalities and differences between the two, a bidirectional servo glue application mechanism was designed. An additional manual intervention station was added, reinforcement station automatic recognition was strengthened, and the welding process was optimized for laser welding (with custom fixtures to accommodate both products). To meet various stacking requirements, an adaptable stacking workstation with automatic recognition for packaging was designed.

Using PLC programming, workpiece numbers are preloaded, and based on the type and size of the workpiece, the corresponding processing program is retrieved, eliminating the need for frequent manual workstation switching.

Three.Customer Benefits

On the customer production line, intelligent robotic arms operate at high speed. Currently, the company is producing elevator components for the Xiong'an New Area Business Center. The company has invested in the transformation of an intelligent production line, enabling the use of industrial internet for one-click backend orders and immediate frontend production, creating a new mode of operation.

General Secretary Xi Jinping pointed out that the new era is an era of struggle. At present, manufacturing companies are working at full throttle, synchronizing production and research and development. With a high-spirited attitude of struggle, everyone is contributing their efforts to the construction of a strong manufacturing city and a strong nation. Similarly, Yawei Corporation is also striving to provide excellent service to every customer on the path of intelligent manufacturing.

Scan the QR code to watch the elevator door panel video.