PConline Culture Sharp Corporation was established in 1912. The company formerly known as "Hayakawa Electric Industries". The product that was founded by Hayakawa Tokuji in Tokyo, Japan, was a mechanical pencil. Its brand name was "Ever-Sharp Pencil." Can always be sharp pen refill. The trademark of SHARP comes from this. In 1923, the Kanto Earthquake destroyed the factory of Tokugawa Hiroshi, and then relocated to Osaka to resurrect. Sharp's headquarters is currently located in Osaka, Japan.
After a century of development, Sharp has now become an industrial group with 50,637 employees and a capital of more than 121.8 billion yen. Earlier this month, we were invited by Sharp to visit its Health and Environment Equipment Business Unit located in Kitasei-machi, Yao, Japan.
Sharp Health & Environmental Equipment Business Division is located at No. 72, No. 3, Kitazawa-cho, Yao, Osaka, Japan. It is responsible for the production and development of "white goods" and "PCI air" purification products. SHARP introduced a number of PCI net ion air purifiers in Japan. The products are also used in air conditioners, refrigerators, fans, washing machines, dust collectors, and hair dryers. In 2012, 40 million home appliances with PCI ion products were sold globally.
After entering the door, it was not the common “front desk†in the country that first caught in the eye. Instead, it saw the solar power generation and trials of the Sharp Health and Environmental Equipment Business Division. This gave us the first insight into Sharp’s corporate philosophy of environmental protection. Feelings.
Sharp introduces us to the internal structure of the third plant of Yachihake Health and Environmental Equipment Division.
After passing through the corridor, the author saw a publicity card. Obviously, Sharp's sales of plasmacluster products reached a new landmark. In 2013, sales of 50 million units were completed.
This is the production process of the refrigerator box that we saw during the visit. I feel that before I enter the refrigerator to produce real scenery, I will provide it to everyone and help you understand the overall production process of the refrigerator.
In fact, the main body of the refrigerator that we visited is roughly the above process (not the complete process of refrigerator production, but it is the most important part). It is divided into six processes, which are:
1. Box steel plate drilling 2. Folding and forming of steel plate 3. Pipe laying and fixing 4. U-shape bending of box 5. Inner and outer box assembly 6. Inner and outer box bonding
The first is the punching and cutting process of the steel plate. Through punching and cutting, the steel plate raw material is pre-punched and cut to facilitate the following process to further process the external housing.
Then the microwave heating of the steel plate, and folding the edge of the box steel plate through the machine, such a role can make the steel plate has a higher rigidity; second, the folds and some of the previous hole positions can be locked with other components, so that The cabinet is firmly integrated with other components.
After the completion of the previous process, the pipeline for the refrigerant is laid. In this step, Sharp employees need to check the position of the copper pipe, because in the next process, there will be machine-stick strips to completely fix the pipeline.
The fixed copper pipe is a sticker fixing process. The tin foil material may be used. The pipe in the figure above is a copper pipe. The refrigerant may flow through the pipe in the finished product. The inside of the steel plate should be filled with a vacuum insulation layer in the future. Therefore, the thermal insulation performance of the sticker should not be too high.
The entire labeling process is done by a robotic arm. The manual adjustment of the copper tube position we just saw is for the robotic arm to accurately attach the fixture to the copper tube.
After the copper tube is fixed, it will be made into a U-shaped box. We can clearly understand the shape of the box of the Sharp refrigerator. The U-shaped box will be sent to the upper floor, where the inner and outer boxes of the refrigerator will be packed and glued together.
The above video shows that the refrigerators delivered to this floor have been assembled with internal and external boxes (including the installation of vacuum insulation, but we cannot see the installation process at this time). At this time, the main body of the refrigerator has been basically completed. As the heavier processes are completed by machinery, their production efficiency is high. Below we will go to the part of the above flowchart that is not covered.
After completing the box body, the workers will manually install some of the important components of the refrigerator, such as compressors and evaporators. Because the refrigeration environment and requirements of air-cooled refrigerators are different from those of air conditioners, although the principles of the two are similar, the difference between the components is still quite obvious. The refrigerant used is R600a refrigerant, which is less common in air conditioners.
Air-cooled refrigerators are similar to air conditioners in that they rely on fans to blow evaporators. Therefore, evaporators are also a very important component. Here, workers will install evaporators, and the instructor picks up a photo for us to see. The fins are very dense and it will be installed near the fan.
The next step is to weld the various interfaces of the refrigeration system.
Pipeline leak check
After welding the pipes, the refrigerator will be sent to the leak detection station where an inert gas filling test will be conducted. We see that the workers installed inspection equipment at the interface to check if there is a leak in the entire pipe. The leak may need to be checked for leaks and then reworked to re-weld.
The leak detection sensor will tell the inspector where it is leaking
The semi-finished products that pass the air leakage test will be sent here for further parts assembly. The workers use the electric screwdriver for positioning and installation. The advantage of the electric screwdriver is that the torque can be precisely controlled to prevent the screws from slipping or being too loose.
Filling refrigerant
After the components are installed, the refrigerant will begin to be filled. Since the refrigerant may be corrosive or toxic, it will be automatically filled in a closed environment.
Install refrigerator circuit boards and other components
After completion, the refrigerator will be sent to another relatively closed workplace for the installation of other components such as circuits.
After installation, the electrical part of the refrigerator is basically completed. We know that in addition to the cooling speed of the refrigerator, another indicator to measure the performance of the refrigerator is the accuracy of the refrigeration, because only the temperature control is relatively steady and accurate to keep the food fresh. The focus of competition on the various refrigerators is here.
We see Sharp's refrigerator circuit is more complex, but its design is very reasonable, the wire interface is located at the edge of the circuit board, control and rectification and transformation are in different areas, most other components use patch technology, its reliability Both stability and stability are better than those of plug-in components.
At this point, the functional components of the refrigerator have been basically installed and will be sent to the next process to complete the installation of the refrigerator door and other products.
Here, the workers finally installed the refrigerator, such as refrigerator doors, drawers, partitions, etc. After installation, it is necessary to affix adhesive tapes to prevent them from bumping during transportation.
After all parts are installed, the seals will continue to be attached because the refrigerator door has a magnetic stripe to absorb the refrigerator box, but its strength is not enough (such as a giant cold room, its quality is not light, and the inertia during transport will be relatively large), and after sealing, the seal will be guaranteed. Nothing is lost in transit.
Finally, the refrigerator is sealed in the outer package, and the refrigerator can be directly shipped to the store for sale. According to the staff, the production capacity of the Yachi Plant can reach 1,700 units per day, showing its production efficiency.
Actually, when we arrived at the Yachi Plant, we saw a batch of refrigerators being shipped out of the office building. From the perspective of their staff, the Yachi Plant mainly produces medium and large-volume refrigerator products. In the high-end products. What we see today is the production process of Japanese-origin refrigerators. So where exactly is Sharp's original Japanese refrigerator? We will unveil the Sharpe refrigerator's eight core technological advantages for everyone in the next technical analysis article, so stay tuned.
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