Haifeng Automation Integrated Solution for Automotive Bumper Stopper Buffer Blocks
Problemas do sector
01
Inadequate safety protection
Imbalanced rigidity ratio and poor energy absorption performance fail to effectively protect the suspension system, nor do they meet pedestrian protection standards.
02
Poor working condition adaptability
Products are prone to damage under harsh working conditions such as extreme temperatures, vibrations, and corrosion. With insufficient durability and a short service life, frequent replacement and maintenance are required.
03
Low production and operation efficiency
Reliance on manual or semi-automated production results in low precision and a high defect rate, making it difficult to adapt to the flexible mass production of multiple vehicle models. Additionally, solvent-based materials lead to excessive VOCs emissions, while molds have poor universality—resulting in high costs and long cycles for vehicle model switching, which limits environmental compliance and customized adaptability.
Núcleo da solução
With over 30 years of profound experience in the polyurethane industry, Haifeng Automation is a veteran enterprise in the polyurethane automation equipment sector. Focusing on the core demands of “safety protection, long-lasting durability, green compliance, and intelligent efficiency”, it integrates independently developed automatic disc polyurethane casting equipment, precision metering systems, and solvent-free PU material technology to create a full-process solution covering “material R&D – modular production – intelligent testing”. The products are compatible with the suspension systems of both fuel vehicles and new energy vehicles. Leveraging technical accumulation in fields such as PU foaming equipment and precision metering systems, it achieves four core goals and provides integrated “technical design + equipment supply + on-site operation and maintenance” services. The equipment boasts a trouble-free operation time of over 6,000 hours, ensuring reliable stability.
Módulos da solução principal
R&D of High-Performance Specialized Materials
Customized protective formulas: Relying on Haifeng’s PU Application R&D Center, specially developed solvent-free PU formulas are created. The material hardness (Shore A 85-95) is precisely adjusted to achieve both excellent rigidity and energy absorption performance, balancing safety protection and operational stability. Furthermore, the material can adapt to extreme working conditions of -40℃~80℃, with no harmful residues and nearly zero VOCs emissions.
Material stability testing: Formula compatibility is verified through multi-component proportioning tests, with a proportioning accuracy of ≤±1%. The products undergo aging, corrosion resistance, and compression set tests to ensure no damage or deformation during long-term use, with a compression set rate of ≤5% and a service life of over 8 years.
Sistema de produção automatizado de processo completo
Integrated production line
Customized complete production lines are provided, covering all processes from raw material pretreatment to finished product output. The core equipment adopts Haifeng's independently developed configuration to ensure material mixing uniformity and production stability, while realizing full-process automated operation.
Customized adaptation
Relying on the CAD modeling capabilities of the Mechanical Design Research Institute, a modular mold design is adopted with a molding precision of ≤±0.3mm. This design can quickly respond to the customization needs of multiple vehicle models, and vehicle model switching can be completed in a maximum of 30 minutes, shortening the production change cycle.
Existing equipment transformation
Haifeng's intelligent temperature control, precision proportioning, and automated conveying modules are installed on customers' existing equipment to realize the transformation from traditional processes to solvent-free environmental protection processes, reducing labor dependence and raw material loss.
Verificação abrangente da qualidade e garantia de conformidade
Intelligent quality inspection
Equipped with Haifeng's independently developed integrated testing equipment, it covers the testing of key indicators such as molding precision, energy absorption performance, and weather resistance. It can accurately identify product defects and ensure that the qualified rate of delivered products meets the required standards.
Real-time control
Haifeng's intelligent production control system is adopted to dynamically adjust production parameters, controlling the product defect rate below 1%. An environmental monitoring module is integrated to achieve nearly zero VOCs emissions, fully complying with environmental standards such as GB 18583 and REACH.
Certification support
Cooperating with authoritative testing institutions, it assists customers in completing multi-standard certifications by providing technical parameters and sample support, helping products meet industry safety and environmental specifications and break through market access barriers.
Valor da solução e efeitos
| Dimensão | Processo tradicional | Solução de automação Haifeng | Efeitos de melhoria |
|---|---|---|---|
| Molding Precision | ±0.5mm | ≤±0.3mm | Reduces error by 40%, ensuring product assembly adaptability |
| Eficiência de produção | 100-200units/hour | 300-500 units/hour | Increases by 2.3 times, meeting mass production needs |
| Defect Rate | 5-8% | ≤1% | Reduces by over 80%, minimizing rework losses |
| Labor Requirement | 4-6 people/line | 1-2 people/line | Reduces by 75%, lowering labor costs and operational error risks |
| Service Life | 5-8 years | ≥10 years | Extends by 60%, reducing replacement costs |
| VOCs Emissions | Excessive | Nearly zero | Achieves environmental compliance, meeting green production requirements |
| Operation Duration | 8-10 hours/day | 24-hour continuous operation | Substantially extend effective operation duration and improve capacity utilization rate |
Processo de implementação
Investigação da procura
A equipa técnica realiza investigações no local para formular soluções personalizadas.
Conceção de fórmulas e processos
Personalização completa e verificação da viabilidade com o apoio do Centro de I&D.
Personalização/Transformação de equipamentos e comissionamento
A fábrica conclui a produção, com os engenheiros a efectuarem a instalação e a colocação em funcionamento no local.
Produção experimental em pequenos lotes
A equipa técnica acompanha e optimiza os parâmetros.
Instalação no local e produção em massa
Implementar a linha de produção e iniciar a produção em massa, fornecendo orientação técnica.
Apoio à inspeção e certificação da qualidade
Ajudar a preencher os pedidos de testes e de certificação.
Operação e manutenção pós-venda
Prestar serviços de manutenção e de atualização com base na rede nacional de serviços.
