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Charging pile assembly line

This production line is a charging‑pile assembly line designed and manufactured by Yalong Intelligent Equipment. It is used for the complete‑machine assembly of high‑power AC/DC charging piles and represents a heavy‑duty flexible assembly system in the new‑energy equipment sector. The core of this line lies in friction‑driven pallet conveyance. The line adopts friction‑roller‑table drive as its core conveying solution.

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The line adopts friction‑roller‑table drive as its core conveying solution. Friction wheels drive tooling pallets to carry charging‑pile cabinets, and the system features accumulation‑release functionality. Pallets can stop and position at workstations while the main‑line drive mechanism keeps running, enabling asynchronous flexible production. It adapts to working conditions characterized by heavy charging‑pile cabinets and uneven assembly cycle times. Compared with conventional plate‑chain lines, it generates less noise, suffers lower wear, and allows more flexible start‑stop operations at workstations.

Workstations are laid out in accordance with the assembly process flow, covering operation units such as cabinet pre‑assembly, power‑module mounting, cable wiring, component installation, complete‑machine commissioning, and power‑on burn‑in testing. KBK rails, balance cranes and assist manipulators are installed above the line for hoisting and moving heavy components including charging‑pile cabinets and power modules. This reduces manual heavy‑load handling and ensures assembly accuracy and operational safety. Each workstation is equipped with work instructions, tool hangers and test interfaces, supporting mixed‑model production of multiple DC fast‑charging piles of different power ratings.

Centered on a PLC, the control system works with stop and positioning mechanisms to achieve precise pallet positioning. It can interface with the plant’s MES production‑management system to realize process flow control, production‑data acquisition and product traceability. The modular design of the friction roller tables facilitates later‑phase workstation addition/removal as well as line modification and capacity expansion.

This line delivers integrated assembly of AC/DC charging piles from loose parts to finished units. It addresses challenges in conveyance, positioning and material handling during the assembly of heavy‑duty electrical equipment, and improves assembly consistency and production efficiency. As key process equipment for the large‑scale manufacturing of high‑power charging devices, it meets the mass‑production requirements of the new‑energy charging‑infrastructure industry.

Charging Pile (CP) Production Line Technical Overview

I. Production Line Configuration

Conveying System：1.8m/2.4m standard segments (Nuogan design).Independent drive per section → each functions as an assembly station (1 CP/station).Upper/Lower lines use KBK hoists and gantry cranes for shell transfer.Empty pallets managed by auto-palletizer → transfer cart → KBK repositioning.Powered Raceway Conveyor (PRC): Tray-based transfer system with quick-change fixtures for multi-model CPs.

II. Intelligent Control Logic

Station Workflow:Next station sensor checks vacancy:If vacant: Press “Convey” button → rollers activate → CP advances.If occupied: Button disabled → system locked.Arrival: Stopper blocks tray → rollers halt automatically.