MANUFACTURING PROCESS
Apex Auto Coolers shall strive to produce defect free and cost effective Radiator Cores, Radiator Components, Complete Radiator Assemblies
RADIATOR ASSEMBLIES AND RADIATOR CORES
On receipt of Raw Materials like, Copper Foils, Brass Foils, Brass Sheet, Tin Ingots, Lead Ingots, Solders etc. before accepting the same at Stores, inspection of these and other items are carried out to check that the materials received conform to the specifications/orders. After the incoming Material inspection, the Stores accept the materials.
After acceptance of the Materials at the Stores, the Raw Materials are then issued to the Production Line.
PROCESS
Copper Foils are issued to the Fin Machine, where foils are rolled through the Fin Machine to make the Fin as per the size and design. Fins are then checked for Slot opening, Equal folding, Straightness, Cut-Off, Length, etc. The Fins are then properly stacked at a specified area.
Brass Foils are issued to the Tinning Machine, where the Foils are coated with Solder on both the sides. The Solder coated Strips are then checked for Smoothness, Solder Coating etc.
After checking, the Solder Coated Brass Foils are then taken to the Tube Drawing Machine, where the Tubes are formed as per the sizes and designs. After the Tube Formation the tubes are checked for Straightness, Seam Lock, Cut-Off, Size of the Tube, etc. and then stacked at a specified area.
C.R.C. Sheets are issued to the Press Section, where the sheets are first checked for thickness & sizes, and the cut sheets are then pressed into trays. After Forming the side channels are then punched for the fan cowl mounting holes and checked for it’s size, formation aesthetics.
Similarly C.R.C. sheets are also issued to the press section for making Radiator mounting Brackets.
Brass Pipes are issued to the pipe cutting section, where the pipes are firstly checked for their thickness and size. The Brass Pipe are then cut as per specified length, and then beaded to from the Radiator inlet and outlet pipes.
Similarly Brass Sheets are issued to the press Section, where the sheets are firstly checked for the thickness and then cut. The cut sheets are then pressed into trays. After Folding Header Plate Trays are then punched as per the requirement and are checked for it’s size, cracks, fully opened slots etc.
The sheets are also cut in sizes for pressing & forming Water Tanks. The formed tanks are then cut to size & are punched with holes for water pipes, filler neck & drain openings.
The Fins and Tubes are taken to the Assembly section, where the Cores are being assembled. The cores are then checked for its Quality, i.e. Fin Damage etc. and also for the Size check, fin and tube check, etc.
After assembling the Cores, the same are sent to the Header Plate Fixing Section, where the Cores are fitted with Header plates at both the Ends. After Header Plate Fixing, the Cores are then checked for proper tube projection at both the ends, Core Right Angle etc.
After the Header Plate Fixing, the Cores are then sent to the Baking Area, where the cores are baked in an Oven, where the time and temperature are pre-set as per the size of the Core. After baking the cores are then taken to the squaring fixture, where pressure is applied on both the sides to make the core Right angled to the Squaring fixture. After Baking and Squaring, the cores are then checked for proper squaring, proper bonding of Fins to the Tubes etc.
After Baking the cores are washed properly to remove the residue and dried properly. After washing the Cores are then taken to the End Dip Section, where the cores are dipped in a solder bath for proper bondage between the Header Plate and Tubes. The cores are then checked for any blocked tubes, fully opened tube slots, equal projections at both the ends etc.
The cores are then taken to the Core Testing Area, where the cores are tested by Air pressure testing under water. If any leakage's are found the same are rectified and re-tested, to ensure leakage free cores.
The Cores are then fitted with Top/Bottom Tanks, Inlet/Outlet Pipes, Filler Neck, Drain Cock, Drain Bush, and Side Frames to Assemble the Cores to the Radiator. The Radiator is then tested by Air pressure under water to detect any leakages. If any leakages are found, then the same are rectified and re-tested to ensure leakage free Radiators.
After testing the Radiators, the same are dried in a Drying Oven and after drying the Radiators are taken to the Painting Section, where the Radiators are painted and dried properly. After painting and drying the Radiators are then fitted with Pressure Cap and the test for Pressure Cap is carried out to ensure for its specified pressure.
The radiator is then dressed for final inspection conducted by the Quality In charge.