The geometry of the soldering-up, the number and the material of collectors are determined by the purpose of the future of the unit. For copper-copper soldering, we use the American solder that does not contain impurities. For copper-steel soldering — solder with 30% of silver in its content.
Cutting of high-strength steel with a sheet thickness from 1 to 10 mm is made in modern equipment with NC. The area of metal cutting produces more than 1 000 kinds of products and parts.
After the test, equipment is transported to the painting area, where all the necessary surfaces are painted. After another inspection, the finished products are sent to the packing department.
Here is the place of HE assembling. The collected packages of HE are sent to the operator of mandrel, where heat exchangers are mandrelled: the expansion of copper pipe by passing the special "bullets" through it – this gives the stiffness to the heat exchanger. Then, the lamella and tube grate are fixed on the pipe.
Lathes with NC process the machined parts needed for the assembly of equipment: nipples, connecting pipes, nuts, the thread is rolled on the jets and, using the technology of thermal drilling, collectors are processed.
Fully assembled and packaged equipment is stored in the depot of finished products until the moment of transfer to the customer or dealer.
Refrigeratory and heat-exchanging equipment is assembled out of junctions and components. The assembled product is tested for the quality and transferred to the packing department and the depot.
Specialists of the department translate the design decisions into programs for production machines of the plant. Adjusted and tested programs are transferred to the machine operators for the production.
The production of TerraFrigo is an organized system, which aims to manufacture products in two areas — refrigerating systems and industrial heat-exchanging equipment.
Design Bureau of TerraFrigo is the centre of local and integrated design of all products, produced by the company. The application of the latest achievements of science and technology lies in the basis of design products. Company designers are developing sketch and technical projects of complex structures, comprise the overall layout and alignment of individual junctions and assemblies. They carry out complex technical calculations for projects, write specs. Design Bureau is the main generation centre, ideas and projects of which are successfully implemented in production.
Department of Technologists
All the design work in the form of 3D models get into the Department of technologists. Further, by using certain mathematical transformations, we develop technological processes of production, means of automation and mechanization, introduce the essential types of equipment. All this ultimately represents the algorithm of production, which is then passed to the operators to the production.
The production area of TerraFrigo is logically divided into operating zones with a total area of about 2 500 sq. m.
Metal Cutting Area
Quality components of metal, required for the production of TerraFrigo, are made independently. About 1 000 kinds of products are made of high-strength steel from 1 to 10 mm. The work of this section is carried out on modern and high-precision foreign and domestic machines with NC: two coordinate-cutting machines, guillotine, hydraulic press, crank press, plasma cutting machine, NC-bending machines.
About 2000 items of products, manufactured at this production stage, are meant for the entire line of products manufactured by TerraFrigo.
Case Production Area
At this stage of production, we produce branded cases for refrigeratory units and air conditioners TerraFrigo. The cases are made in the vacuum-forming machine. This process has three main components: matrix, material, and vacuum. Thermoplastic material, which later becomes the case, is heated up and becomes liquid. Then, using vacuum, the material takes the desired shape, and we achieve a complete wrapping of the matrix. Having cooled down, the material "remembers" the form of the matrix, copying the configuration.
Production Line of Heat-Exchanging Equipment
Production lines of TerraFrigo are equipped with modern equipment, allowing to produce heat exchangers of various modifications with different geometry.
The production of heat-exchanging equipment is a complex and multistage process. It begins with the preparation of raw material.
The machine for the production of a tuning fork – U-shaped pipe, unwinds a copper pipe out from coils, cuts and bends it. All manipulations occur automatically, which eliminates the possibility of spoilage. In parallel with the preparation of the pipe, lamellas are made in the press with NC. The program with the future geometry of the heat exchanger is loaded into the computer. After this, foil is supplied from a roll. After 10 seconds, we get the stamped lamella. Assembly of HE is the next stage of production. According to the approved drawing, the operator of the area collects a package of heat exchanger, installs tube grate, made to coordinate notchers, and transmits the packet to the operator of mandrel.
The process of mandrelling is an extension of the copper pipe, by passing special "bullets" through it. This gives the heat exchanger the stiffness, lamella and tube grate are fixed on the pipe.
Then, almost finished HE is transferred to the soldering area. The geometry of the soldering-up, the number and the material of collectors are determined by the purpose of the future of the unit.
For copper-copper soldering, we use the American solder that does not contain impurities. For copper-steel soldering — solder with 30% of silver in its content. To improve the quality of soldering, the strength of seams, the cleanliness of the inner surface, all heat exchangers are soldered under nitrogen using a flux.
100% of the produced heat exchangers are subject to rigorous quality control. Quality Control Department tests the tightness, according to the drawing, the absence of oxide on the soldering, and the quality of the seams.
Assembly Area of Finished Units
All the necessary components, including those produced by the plant, get from the depot to this area. Then, professional craftsmen, according to the approved drawings and technical cards, perform a multistage process of creating the finished units. Quality Control Department closely follow their work in this area, checking the conformity of the products to the technical documentation at the test points.
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