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2025
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05
How the Teabn T06 reinvented the standard for air conditioner enclosure painting
Tianjin Teabn Coating Electromechanical Co., Ltd T06 series for the HVAC industry launched a professional solution, through the adaptive spraying system to achieve the sheet metal bending ± 8μm film thickness control, optimize the powder coating process in the gap of the heat sink. Verified by many customers, it can reduce the rework rate by more than 30%, increase the utilization rate of powder to 95%, and provide full-process services from equipment selection to process optimization.
First, the quality dilemma of the HVAC industry
The 2023 Industry Quality Report showed that air conditioning product appearance problems accounted for 42% of after-sales complaints, most of which stemmed from defective coating processes. A medium-sized air conditioning factory had a single recall loss of 1.8 million yuan due to bulk coating peeling. Behind these pain points are three core issues that need to be addressed:
The first is the spraying blind spot brought about by structural complexity. The air conditioning shell is bent at various angles, and it is difficult to maintain a constant distance with a traditional spray gun, resulting in a thin coating on the corners. The distance between the heat sinks is usually only 2-3mm, and ordinary spraying can not ensure complete coverage.
Second is the challenge of durability in harsh environments. Air conditioning outdoor machine to withstand the sun and rain, ordinary coating in the hot and humid environment is prone to blistering off. A brand in the Hainan market research shows that the use of 2 years after the coating problems accounted for as much as 37% of the product.
Finally, the production side of the efficiency bottleneck. Multi-color spraying requires frequent color changes, each time the downtime cleaning leads to loss of production capacity. An enterprise statistics show that only the color change process takes up 15% of the production time.
Second, the way to break through the T06
Faced with these industry challenges, Teabn's technical team has introduced targeted solutions after three years of research and development:
In terms of hardware design, the T06 series adopts a 270-degree rotatable gun head structure with an intelligent distance sensor. When the bending part is detected, the system will automatically adjust the amount of powder and electrostatic parameters. After application by a customer in Guangdong, the difference in coating thickness at the bending area was reduced from the original 30μm to within 8μm.
Narrow focusing nozzle and auxiliary electrostatic device are developed for heat sink coating. By adjusting the ratio of airflow, a more concentrated cloud of powder is formed. Test data from a heat sink factory in Zhejiang showed that gap coverage increased from 68% to 93% without affecting heat dissipation efficiency.
In terms of process control, Taipen has established a complete set of parameter database. According to the characteristics of different materials and structures, the optimal spraying program is preset. New employees can get started after simple training, dramatically reducing human operation differences.
Third, the transformation of the case record
The transformation of an air conditioning OEM factory in East China is most representative. The factory has long been an OEM for international brands, but the spraying pass rate has been hovering around 85%. After the introduction of the Taipen program, it went through three stages of transformation:
The first phase replaced the core spraying equipment with the T06 series multi-gun synergistic system. This alone increased the daily production capacity from 800 units to 1,200 units, while reducing the powder consumption per unit by 12%.
The second phase optimizes the process flow and establishes standardized work instructions. Video analysis revealed that irregularities in the operator's gun holding angle were the main variable. The addition of an auxiliary positioning device resulted in a significant improvement in product consistency.
The third stage implements digital management and real-time monitoring of key parameters. Now the plant's spraying pass rate is stable at over 98%, and it has become the brand's gold-medal supplier.
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