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Automated air conditioner filling station

  • Front view
  • Adapter

Automated air conditioner filling station is used for filling air conditioner in a car in assembly line when car produce

Price: from 140 000 USD (export price without VAT)
  • Specification
  • Features
  • Benefits
  • Description

    APPLICATION AREAS

    Automated filling stands are used for filling cars with technical liquids and gases (such as hydraulic, engine and transmission oils, coolant and freon) in conditions of conveyor assembly at the manufacturer's factory.

    FILLING STATION CONSIST:

    • The stations consist of a hardware cabinet, a control cabinet and a hose line with a refueling adapter and a control handle.
    • They have high productivity, refueling accuracy and repeatability of cycles.
    • Convenient refueling adapter with integrated stand controls;
    • Own software in English, customized to the customer's requirements;
    • Control system based on components from Siemens, Omron, Allen Bradley, etc

    CONTROL CABINET

    1.The signal column with an audible siren is designed to indicate the current state of the installation.

    2.The visualization panel is used by the operator during operation to display various process parameters and installation configurations. The panel is also used by service personnel when debugging the stand

    3.Main electric switch. Fully turns on/off the power supply of the stand.

    4.Illuminated button (green) – "START CYCLE". Initiates the automatic refueling process.

    5.Illuminated button (green) – "CONTROL VOLTAGE ON". Turns on the control voltage of the installation.

    6.Indicator light (red) – "NETWORK". Signals the connection of the installation to the electrical network.

    7.Indicator light (red) – "CONTROL VOLTAGE OFF". The control voltage is off.

    8. Button without backlight (red) – "STOP CYCLE". Interrupts the automatic refueling process.

    9.Illuminated button (red) – "RESET ERROR". Blinks when there is an error. When the cause of the error is eliminated and pressed, it resets the error.

    10. Indicator light (white) – "TANK REPLACEMENT". Warns the operator about the need to replace the refrigerant tank.

    11. Indicator light (red) – "EMERGENCY STOP". Warns the operator when the installation enters the emergency stop mode.

    12. Mushroom button (red) – "EMERGENCY STOP". Causes an emergency shutdown of the installation.

    13. Button without backlight (red) – "LAMP TEST". Checks the operability of all installation lamps.

    14.Indicator light (white) – "MAINTENANCE". Signals the need to call maintenance personnel and perform maintenance work.

    15. Receipt printer. Gives the operator the results and parameters of refueling the car.

    16. Barcode reader. It is intended for initializing the model of the car that arrived at the gas station and determining the necessary parameters of refueling.

    DESCRIPTION OF THE STATION OPERATION

    The operation of the installation is provided by a PLC-based control system. The program stored in the non-volatile memory of the controller ensures the execution of the entire algorithm of the complex systems. The indication of the parameters of the refueling process is displayed on the operator panel.

    The algorithm of the installation for refueling the car air conditioning system:

    1) Switching on the main electric switch, switching on the control voltage, compressed air supply (control by pressure regulator No. 1), nitrogen supply (control by pressure regulator No. 2), the presence of oil in the vacuum pump (control by oil level sensor), the absence of overheating of the piston compressor (control by temperature sensor), the presence of PAG oil in oil tank (in the absence of a warning is issued to the operator and oil refueling is not performed), errors are reset or absent.
    2) Starting the vacuum pump.
    3) Refilling the battery with R134a refrigerant to a pressure up to 17 bar (the function is mandatory, controlled by a pressure sensor).
    4) Cleaning of the vacuum line.
    5) Removal by the operator of the adapter from the lodgment (monitoring by the sensor in the lodgment).
    6) Installation of the adapter and fixing of high and low pressure hoses with the help of quick replasement adapters to the mains of the car air conditioning system.
    7) Initialization of the refueling cycle by the operator.
    8) Preliminary check of the absence of excessive freon pressure in the car's air conditioning system / protection against refueling the car (the function is mandatory controlled by a pressure sensor).
    9) Preliminary check of the system for tightness to the level of residual pressure of 200 mbar (the function is mandatory, controlled by a pressure sensor, the tightness of the installation of the quick-release adapter connections to the vehicle mains is also monitored by the operator).
    10) Crimping of the vehicle system with compressed nitrogen to an excess pressure of 17 bar (the function is switched off, controlled by a pressure sensor, can be excluded from the automatic refueling mode). When using this function in production, it is necessary to connect the stand to the main line / cylinder with compressed nitrogen.
    11) Removal of gases from the air conditioning system to a residual pressure level of less than 5 mbar (a mandatory function, controlled by a pressure sensor DV).
    12) Control check of the system for tightness (the function is mandatory, controlled by the pressure sensor DV).
    13) Ultimate vacuuming of the system (a mandatory function, controlled by a pressure sensor DV).
    14) Filling of the air conditioning system with PAG oil using a volumetric dispenser with an accuracy of 1.5% (the function is switched off, controlled by a flow sensor, can be excluded from the automatic refueling mode).
    15) Refueling of the air conditioning system with R134a refrigerant using a mass flow sensor with an accuracy of 1.5% (the function is mandatory, controlled by the flow sensor).
    16) Stopping the refueling cycle.
    17) Unclench the adapter, return the adapter.
    18) Cleaning of the filling line.
    19) Cleaning of the vacuum line.
    20) Returning the control system of the installation to its original position.

  • Technical characteristics
    Parameter Value
    Electrical power, V/Hz 

    ~ 3х380/50

    Power consumption, kWt, no more than 2
    Work air pressure,bar 5.0 ~ 6.0
    Maximal air pressure, bar 8.5
    Compressed air consumption, nl/min, no more 2000
    Vacuum pump productivity, m3/h 24
    Oil level sensor in the vacuum pump integrated
    Remaining pressure during vacuuming, mbar, no more 5
    Filling pump productivity, L/min 50
    Maximum pump filling pressure, MPa 25
    Filling working pressure, bar 15…17
    Working environment of the liquid circuit Freon R134a (others on request)
    Capacity of the internal tank for working fluid (gas), l. 3,0
    Applicable refueling volumes1),kg.
    0.5;0.8;1.5 (others on request)
    Flow meter accuracy, %
    1,5 (others on request)
    Tact-time of the technological process, s, no more 1) 280 ... 500
    Adapter weight, kg.

    1,3 ... 2,0

    1) It is configured during the start-up process.

    OPERATING CONDITIONS

    Enviroment temperature +10 …+40 oС
    Humidity relative, % 30…80

    DIMENSION AND GROSS

    Dimension, LхWхH,mm 850х1616х2012
    Netto weight, kg., no more 675

    GARANTE

    Garante:  12 month
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Automated air conditioner filling station