Syfeng has created a full-process automation solution integrating die-casting, baking, winding and testing for Huawei's magnetic ring production, which empowers the large-scale production of magnetic rings by focusing on high-precision, high-security and high-efficiency collaboration.

Full-process automation, covering key production links

This solution deeply integrates the whole chain of magnetic ring production, controls the quality and efficiency from the source, and the core tasks cover seven major links:

lRealize automatic loading and unloading of die-casting machine, and simultaneously complete the machine dust cleaning to ensure a clean production environment;

lAccurate implementation of product demolding operation, at the same time thoroughly clean the mold, to protect the stability of subsequent production;

lAutomatically send the product into the oven for baking, and accurately discharging to the peripheral working stations of the equipment after completion;

lDouble winding (wire diameter 0.25mm) for the magnetic ring to ensure the precision and consistency of the winding;

lStrictly control the pins after winding, and use the laser peeling process;

lCarry out magnetic loss test (single channel 10min/pcs) to ensure that the product performance meets the standards;

lFinally, the material is discharged according to the serial number batch to realize the orderly management of the products.

Upgraded core processes for efficiency and safety

The solution carries out a number of optimizations on key processes and equipment layout, significantly improving production efficiency:

lPrecise control of key process parameters: powder loading interval of 2.5h, core discharging interval of 2h, die-casting time of only 5min, powder tray capacity of 35PCS, core tray capacity of 200PCS, the mold adopts a combination of copper brush + air blowing cleaning method, to ensure the stability of the production rhythm.

lFour core upgrading highlights: replace the industrial robot with a collaborative robot, greatly improving the safety of personnel operation; add a new copper brush cleaning station to strengthen the effect of mold cleaning; the powder cake and magnetic ring loading and unloading concentrated in the same side, reducing the cost of personnel walking; upgraded to the upper and lower two levels of zone-controlled ovens, baking process to achieve the flexibility of the control.

Integration of winding and testing to ensure product quality

Magnetic winding and testing links focus on precision and reliability, the key configuration is as follows:

lWinding and testing parameters: the winding is automatic (wire diameter 0.25mm), with laser stripping process; magnetic loss test single-channel time-consuming 10min, the size of the discharging tray is 305*212*25mm (a total of 90 frames), the time to change the disk 1.5h, to ensure efficient flow.

lProcess optimization design: the material flows along the path of “loading → winding → peeling → testing → sequential compartmentalized tray”, setting up two test stations and reserving manual testing area to meet diversified testing needs; transferring materials through collaborative robots to enhance operational flexibility, while increasing the pin fixation scheme to ensure processing stability.

Precision component design, highlighting the details of craftsmanship

The program focuses on flexibility and compatibility in the design of core components to meet complex production requirements:

lCleaning and demolding components: the copper brush cleaning components are independently driven by dual motors, up and down height adjustable, the molds are pushed to the cleaning position by cylinders; the mold release agent nozzle and dust removal module can flexibly adjust the spraying position to adapt to different mold scenarios.

lWinding and Positioning System: All self-made winding machine contains hook rod, positioning cylinders and other components, when winding through the left positioning hook to accurately fix the wire and pins; magnetic ring positioning fixture designed for 10mm OD, the tail cylinder stroke is adjustable, compatible with a certain size change; for 0.25mm wire diameter using replaceable hooks for easy maintenance and adaptability.

lTest Connection Guarantee: The test station is connected to external or built-in testers through flying wires, equipped with spring-loaded positioning copper plates to ensure the stability and reliability of the test process.

This solution provides efficient, safe, and reliable intelligent equipment support for Huawei's magnetic ring production through full-process automation control, key process upgrades, and precision component design, helping to realize large-scale, high-quality production.