The high-voltage DC contactor automatic flexible production line produces three DC contactor models on a shared line. The entire line covers the complete process flow from component assembly, cold welding, ceramic-assembly machining, semi-finished-product performance testing, dual-station laser welding, helium mass-spectrometer leak detection, gas charging/discharging, coil magnetic-assembly assembly, electrical running-in, comprehensive characteristic testing, preheating & potting, tunnel-type baking & curing, loop-resistance testing to appearance inspection and packaging.

The line is configured with 20 process units, including multiple dedicated automatic machines and a few manual stations, and is equipped throughout with core devices such as CCD vision inspection, ionized-air cleaning, an INFICON helium mass-spectrometer leak detector, a 500 W laser welding machine and a tunnel curing oven. It supports tray-AGV material docking for loading; key processes — weld quality, riveting gap, label position and potting weight — are all automatically inspected; semi-finished and finished products undergo full electrical/mechanical performance tests including pick-up/release voltage, contact gap & overtravel, contact resistance and reaction force; each unit scans codes to identify the product model and automatically calls the corresponding process recipe; key assembly and test data are acquired and stored, enabling product quality traceability.

The line is designed with a cycle time of 12 s/unit and an uptime rate ≥90%, staffed by 6–7 operators for replenishment, partial pre-assembly and packaging.

Figure: High-Voltage DC Contactor Automation Equipment — Layout / Equipment Schematic