It’s tough for glass fabricators to know the full process of how a glass washer is built even you have visited the supplier’s factory. You will have a better concept on quality if you can understand the manufacturing process, which can help you for a wise decision on purchasing.
The manufacturing process is split into fabrication (making parts), sub-assembly (putting parts together to make components), and assembly (putting the components together to form the final product). The fabrication process comprises several different procedures, each specific to a particular type of raw material—metal, plastic, or aluminum. Once the constituent parts have been made, they are assembled; major sub-assemblies, or components, include the transmission, the pump, the blower and other electrical parts. Finally, the sub-assemblies are put together, which is then complete.
1. FABRICATION
Many parts of a washing machine are manufactured from steel, stainless steel and rubber rollers. Majority of the washer manufacturers in China purchase these parts from other suppliers. TECHWIN is could be the only one who owns metal processing workshop and rubber rollers manufacturing factory itself. Parts produced in house for easier and better quality control.
Stainless steel:
Raw materials will be purchased in bulk order. Stainless steel is an important part of the machine, a special liquid will be applied to test its quality, light yellow means it’s SUS 304. If it’s SUS 201, the liquid will become pink or red. Some dishonest metal processors offer 201 to those manufacturers who actually paid for 304, then the victim will be customers buying the washers eventually.
Then these metal sheets will be cut or bent, as per sizes in different models. An imported advanced laser cutting machine makes cutting preciously, patterns and edges will be exactly same as technical design. With the help of the bending machine, metal sheets are bent or stretched in different shapes.
Welding:
By welding separated pieces of steels cut in strict compliance with the spec, the chassis of a machine is built to exact balance to decrease glass breakage in the production. One important step we take before welding is to process the surface to remove the rust, by which is the machine is made to stand the tear from water.
Even the machines are advanced automatic ones, providing precise results and a high degree of reliability. Our experienced technician will check on the finished products, to ensure it 100% fit for the washing machines.
Rubber roller
All the rubber rollers used in TECHWIN washers, their shafts are made of 3mm thick seamless iron or stainless steel pipes. Seamless pipe is formed by drawing a solid billet over a piercing rod to create the hollow shell. As the manufacturing process does not include any welding, seamless pipes are stronger and more reliable than welded pipes. Unlucky that the market flooded rollers with 2mm thick welded pipes, you can not expect to use the washer for 6 -10 years. Such rollers will get bent easily, especially for washers up to 2000mm width. It’s meaningless to ask your supplier about it unless you can see the raw materials in their workshop.
The seamless pipes will be cut into pieces in needed length. They will be taken to balance to reduce vibration. Spindle axle ends will be welded on two sides of the shafts, by a skilled and proficient welder. Getting the spindles perfectly parallel and true to each other is the difficult part. Thanks to the modernized CNC machines, we have get out of this troubles already.
Once the shafts passed QA check, they will proceed to the covering stage. A mixer is used to mix rubber powder and other ingredients. For the rubber rollers made by TECHWIN, its rubber content is up to 40%. Even you use the machine for 5 years, the roller surface will be still elastic. But others will use only 30% or less rubber, the rubber on the rollers will fall off for around 2 years. Then you need to pay large amount and wait for a long time for replacement.
After dyeing, the rubber will be cut into pieces. The rubber bars will be injected on the surface of the shafts, for more intensity and higher strength. Then they will be taken to high temperature processing. Final step is surface grinding. In our work shop, the rollers will be polished for twice to obtain smooth surface and better concentricity. Care and attention to precision is paramount to our grinding process. While others will just grind the rollers for once to save time and labor costs.
2. SUB-ASSEMBLIES
Electrical parts in our washers, like motors for transmission, brushes and pumps, are the ones shopped from famous brands. For example, Siemens, Schneider and etc. We use these brands for the reason of quality, and also for easy access in local markets for customers.
Control panel and electrical cabinet manufacturing are done manually, including engineering and lay out; punching and drilling the back panels and enclosures; cutting, stripping, crimping and labeling the wires; installing the components; and wiring the panels. Techwin’s highly trained operators are fully certified Cable Assembly Specialists. The quality and detail of our team is unparalleled in the cable assembly field.
3. ASSEMBLY
From small simple sponge washers to high-end complex disk brush washing machines, our engineering and assembly specialists produce durable, efficient machines designed to withstand years of service, along with strict adherence to quality processes and standards. The working process is as below:
* Plan assembly procedures, following specifications and assembly manuals, along with planning the fabrication and alteration of existing parts or processes to complete equipment that has been ordered with required features.
* Set up the chassis of the washer, fix the stainless metal parts on the machine frame.
* Install moving parts, such as rubber rollers, screw rods, or bearings, and work them to test free movement.
* Troubleshoot equipment failure, design deviations, incorrectly made parts, etc., and resolve problems to complete the process in a timely manner。
* Test and commissioning of completed machine.
4. QUALITY CONTROL
All parts purchased from outside manufacturers are spot checked before use, and most sub-assemblies are checked as well. For instance, all pumps are leak-tested. All painted parts are visually inspected for defects. Once it has been completely assembled, the machine is filled with water in tanks and tested for speed, noise, vibration, and visual defects, as well as properly functional controls and mechanisms, by our technicians who have at least 6 years experience in this field.
For those who need to work in production, their cabinets will be taken to inline coordination test if suppliers for other machines in the line is nearby. The machine will be cleaned before packaging.
It’s not finished yet. Maybe you are far away to travel to our site for final inspection before shipping, don’t worry, our sales team will take the responsibility and be your eyes.
Videos will be recorded, as well as pictures for each part of the washer. Then a detailed quality report will be sent to you for confirmation. Machine can be packed only with your confirmation. Ensure the machine arriving to your plant will be qualified.
Talk to franky@fstechwin.com to get wonderful experience on our quality and service.