EV charging piles are categorized into wall-mounted and floor-standing cabinet-type units, covering full-range AC and DC charging specifications. Standard power grades include 7kW, 11kW, 22kW low-to-medium power AC chargers for residential and commercial parking scenarios, as well as 60kW, 120kW, 180kW, 240kW high-power DC fast charging piles for commercial public charging stations. To achieve standardized, high-volume and mixed-batch production of different EV chargers, we deploy two dedicated and mutually independent charging pile assembly line configurations: double-speed chain lines for lightweight wall-mounted AC chargers, and heavy-duty friction roller lines for floor-standing cabinet-type AC and DC charging piles. This segmented production layout ensures targeted manufacturing accuracy, load adaptability and production efficiency for different product specifications.
1. Double Speed Chain Assembly Line for Wall-Mounted AC Charging Piles
Wall-mounted AC charging piles feature lightweight and compact structure, which are exclusively produced on circular double-speed chain assembly lines. Equipped with dedicated tooling pallets, the conveyor runs at an adjustable speed of 0.3m/min to 1.5m/min to match fine assembly processes. Each workstation is fitted with a jacking stopper mechanism, which locks pallets precisely in position without stopping the entire line, supporting manual assembly and automated bolt tightening operations.
The complete production flow covers housing assembly, electronic control module installation, touch screen calibration, wiring harness arrangement, high voltage withstand test and full functional debugging. After passing all performance tests, finished products are packaged and discharged from the line end. The circular loop design supports flexible mixed production of 7kW, 11kW and 22kW wall-mounted chargers, with a model changeover time of only 20 minutes, fully adapting to small-batch and multi-variable production orders.
2. Heavy-Duty Friction Roller Assembly Line for Floor-Standing Cabinet-Type Charging Piles
The on-site workshop equipment shown in the picture is a dual-lane friction roller charging pile assembly line, specially developed for heavy cabinet-type charging equipment. This linear production system is only applicable to floor-standing high-power AC chargers and DC fast charging piles (100kg to 300kg per unit), and cannot be used for lightweight wall-mounted charging pile production.
On-Site Hardware Configuration & Industrial Design Details
The workshop is equipped with two parallel independent total assembly lines (Line 1 and Line 2), adopting a straight-line progressive layout different from circular double-speed chain lines. An overhead truss-type light gantry crane system covers the entire working section of the lines, providing auxiliary lifting for heavy power modules and cabinet components to reduce manual handling intensity. Tri-color stack lights are installed at the end of each gantry to display real-time line operation, standby and fault alarm status.
Each workstation is equipped with industrial display terminals connected to the factory MES system, realizing real-time monitoring of production output, product yield, cycle time and equipment operation status. Matching on-site HMI operation screens facilitate on-site parameter adjustment and process control for operators. The workshop is equipped with standard safety guardrails and safety warning signs, complying with new energy equipment production safety specifications. Meanwhile, height-adjustable assembly platforms are configured at each station, allowing operators to adjust the cabinet working height freely, which optimizes the ergonomics of internal wiring, module installation and cabinet assembly operations.
Technical Parameters & Production Process
The friction roller conveyor runs at a constant stable speed of 0.5m/min to 1.0m/min, with reliable heavy-load bearing capacity. Before entering the final assembly line, cabinet shells are processed through laser cutting, sheet metal bending and integral welding forming. In the assembly stage, robotic arms cooperate with the gantry system to complete precise lifting and positioning of heavy charging modules, while operators finish high-voltage cable connection, control board installation and peripheral component assembly.
After assembly, products are transported to the professional test platform via friction rollers for full-power load testing, insulation performance detection and aging verification. Only products that pass all electrical performance tests will be transported to the line-end output area and directly loaded and shipped by forklifts without additional offline packaging procedures. In terms of production capacity, this heavy-duty assembly line can stably produce more than 100 units of 120kW cabinet-type DC charging piles per day, balancing heavy-load transportation stability and high-efficiency mass production.
Line Matching & Production Adaptability
We adopt differentiated charging pile assembly line configurations based on product structural characteristics. Light-duty double-speed chain lines are targeted at small wall-mounted AC chargers with flexible model switching; heavy-duty friction roller lines are specialized for high-power cabinet-type charging piles with strict requirements on load capacity and assembly precision. The overall workshop realizes centralized production of full-series AC and DC EV chargers through line classification, effectively reducing production costs, improving product consistency, and meeting both customized small-batch orders and standardized large-scale production demands.
