8-800-350-43-01
toll-free number in Russia
toll-free number in Russia
HOW COMFORT IS MADE: PRODUCTION STAGES
1. MATERIAL AND CONTROL
The AK12M2 alloy (aluminum- silicium -copper) is used for the production of aluminum radiators, the alloy is characterized by high fluidity and elasticity and consists of 98% of russian raw materials.
The aluminum alloy is controlled in the plant's own laboratory on special equipment by spectral analysis. where the compliance with the requirements for chemical composition and structure is checked
The aluminum alloy is controlled in the plant's own laboratory on special equipment by spectral analysis. where the compliance with the requirements for chemical composition and structure is checked
2. ALUMINUM MELTING
The metal melting shop is equipped with five melting furnaces of both shaft and dosing type. The equipment "Marconi" (Italy) provides a continuous supply of molten (700 degrees Celsius) aluminum alloy. About 15 tons of metal are melted daily.
3. HIGH-PRESSURE CASTING
The section casting division is equipped with three automated casting complexes based on the Bühler-840 EcolinePro machine (Switzerland) and two automated casting complexes based on the YIZUMI ZJ001 machine (China). Double molds are equipped with a temperature control system and serviced every 40,000 strokes.
The implimentation of KUKA robots (Germany) and automatic waste strippers made it possible to automate the process and increase the productivity of casting complexes.
The implimentation of KUKA robots (Germany) and automatic waste strippers made it possible to automate the process and increase the productivity of casting complexes.
4. Mechanical treatment
The mechanical treatment of sections has a closed automated cycle of production processes. The treatment and assembly of heating radiators is carried out with use of automated lines "Gi-ZetaImpianti" (Italy) and "SAIP Srl" (Italy).
Technological stages:
Technological stages:
- welding of the bottom;
- polishing of the "head" of sections;
- polishing of the front and back surfaces of the section;
- facing and threading in the horizontal collector section;
- extraction of chips from the cavity of the section;
- assembly of radiator sections;
- checking the assembled radiator for tightness under pressure that is one and a half times higher than the maximum operating pressure
5. PRESSURE TESTING OF RADIATORS SECTIONS
Pressure testing of sections is carried out on special equipment as follows: the section is immersed in water and checked by air flow at a pressure of 30 Bar, appearance of bubbles is a consequence of leakage, such a section is considered to be defective and is rejected. Sections that passed the test after the pressure test stage are conveyed to the radiator assembly stage.
6. ASSEMBLY AND PRESSURE TESTING
Assembly is performed on special equipment, connection is made by nipples, and leak tightness is ensured by rubberized asbestos fabric gaskets. After assembling, the readymade product is placed on the pressure test stand and checked for defects. The air pressure on the stand is at least 24 Bar. This is enough to detect a defect.
7. DEGREASING AND COATING
After assembling the finished product goes to the site of preparation for painting.
The first stage is chemical degreasing by jet method under the pressure of 1.5 atmospheres.
After degreasing, a conversion anticorrosive coating is applied by method of dip coating
The first stage is chemical degreasing by jet method under the pressure of 1.5 atmospheres.
After degreasing, a conversion anticorrosive coating is applied by method of dip coating
8. POWDER COATING
Upon surface preparation, anaphoretic primer is applied to the radiator and then it is dried in an oven at a temperature of 190 degrees Celsius.
Dyeing is performed by applying a glossy powder polymer paint in the automatic dyeing chamber using an electrostatic field and subsequent polymerization in the oven at a temperature of 200 degrees Celsius
Dyeing is performed by applying a glossy powder polymer paint in the automatic dyeing chamber using an electrostatic field and subsequent polymerization in the oven at a temperature of 200 degrees Celsius
9. PRESSURE TESTING AND PACKAGING
After applying the polymeric coating, acceptance tests and the second leak tightness testing are carried out under a pressure that is one and a half times higher than the maximum operating pressure.
A technical passport with the date of manufacture and serial number is attached to the finished radiator. The products are packed according to GOST, which ensures safety during transportation and storage.
A technical passport with the date of manufacture and serial number is attached to the finished radiator. The products are packed according to GOST, which ensures safety during transportation and storage.
