Electric Bus AC System workshop utilizes a digital, flexible production line with modular design at its core, integrating intelligent testing and lean management to achieve end-to-end quality control from component assembly to system debugging.
Its production system emphasizes “flexible adaptation” and “intelligent diagnostics,” capable of simultaneously meeting the customized air conditioning needs of 12 types of vehicles, including buses, long-distance buses, and school buses, with an annual production capacity of 150,000 units.
Electric Bus AC System Production Line Layout: U-shaped Unitized Production Mode
The workshop employs a U-shaped modular production line (a total of 6 main production lines). Each unit focuses on a specific functional module (such as a refrigeration system, heating module, and intelligent control unit), achieving seamless process connection through AGV unmanned transport.
Electric Bus AC System Core Production Units:
Compressor Assembly Unit: Equipped with an automatic torque tightening machine (accuracy ±1 N·m), performing 100% airtightness testing on the compressor and condenser interfaces (pressure holding test 2.8 MPa, leakage rate <0.5 g/year);
Air Duct Forming Unit: Utilizes 3D laser cutting (positioning accuracy ±0.1 mm) and robotic welding to ensure uniform airflow in the top-mounted dual evaporator air duct (wind speed deviation ≤8%);
Intelligent Assembly Unit: Integrates a vision recognition system to automatically match the vehicle model database (e.g., an 11-meter CT bus requires 4 indoor units), guiding workers to complete the assembly of the zoned temperature control modules.
Flexibility Highlight: Through rapid changeover design (changeover time <30 minutes), the same production line can switch between producing air conditioning systems for traditional fuel vehicles and heat pump systems for electric buses, meeting Yutong’s “same platform for fuel and electric vehicles” strategic requirements.
Key Processes and Quality Control of Electric Bus AC System
Modular Pre-assembly Technology. Utilizing a “large module pre-assembly + final assembly integration” process, Electric Bus Air Conditioner is broken down into 5 pre-assembled modules:
1. Refrigeration Module (Compressor + Condenser + Expansion Valve)
2. Heating Module (PTC Heater + Waste Heat Exchanger)
3. Ventilation and Purification Module (G4 + HEPA two-stage filtration)
4. Electrical Control Module (Dual-core MCU + Sensor Group)
5. Top-mounted Housing Module (Carbon Fiber Composite Shell). Each module undergoes independent testing (e.g., the refrigeration module requires passing high and low temperature cycle testing from -30℃ to 55℃) before entering the final assembly line for integration, significantly reducing final assembly complexity (final assembly time is reduced to 65% of traditional processes).
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