The plant covers an area of more than 6 thousand m2 and achieves a monthly output of over 400 sets of carbon fiber frames.
2 filament cutting machines are equipped to cut the carbon fiber materials into rectangular, square, triangular and irregular shapes.
The rolling process mainly involves rolling the cut carbon fiber materials on the molds.
We possess 4 modeling machines that accomplish the compression modeling performance upon the molds, about 70-80 minutes and a temperature of 150±5℃ are needed to finish the molding.
The molded semi-finished products and the accessories will undergo the gluing process by the high-temperature plastic.
For the smoothness and aesthetics intention, we polish the carbon fiber frame accessories.
The labeling process can be done according to clients' requirements.
We spray the gold oil, the paint and the paint finishes sequentially to make the surface brighter and anti-oxidation.
The automatic processing is performed upon the 5-way accessories by the fully automatic 5-way drilling machine.
With 8 punching machines, the punching process upon the upper, middle and lower tubes is perfectly done.
The grooving, punching and molding process are performed upon the pipes.
The plant is staffed by over 200 skilled employees and reaches a monthly output of near 50 thousand sets.
Pulse welding is adopted to process the front triangle and the back triangle, endowing the products with high pilot arc performance, good anti-hole performance and excellent anti-corrosion performance.
In order to raise the hardness of the frames, the heat treatment which consists of the steps of T4 (solid solution) and T6 (annealing) will be done. During the T4 step we control the temperature at 540℃, and the time within 90 minutes. Then a correction will be taken. Finally the T6 step with an appropriate temperature of 195℃ and a processing time of 240 minutes will follow.
Polish the frames to make the surface smoother.
The cleaning process features 4 steps. Firstly a pre-degreasing treatment will be given to remove the oxides, dust and grease on the surface. Then we do the main-degreasing job, after which the remaining solution on the surface will be gone. Next with the environmental protection coating treatment technique, we attempt to foster a protective film on the aluminum material surface to protect it from oxidized. Finally we clean the products with water.
The workshop possesses about 25 personnel whose average working experience is over 5 years. The painting treatments of all of the parts that need to be painted are done here.
Fix the wires on the pipes.
The electrostatic painting and artificial modification process
With a dozen assemblers who have accumulated over 5 years' industrial experience, we have the absolute capacity to assemble 10 thousand wheelsets per month.
The workers are fixing the spokes on the wheel hub.
Mount the spokes on the rims. The rims can be divided into 16-hole, 20-hole, 28-hole, 36-hole and 72-hole types.
2 wire wheel tensioning machines are equipped to lock the spokes tightly. For one wheel only 12s is needed.
The dimension deviation of the wheels is controlled within 1mm by the automatic wheel correcting machine.
Fit and pump the tires.
The assembled wheels.
Shown are our workers assembling the city bikes. With the advanced pipelined techniques and over 40 personnel possessing over 5 years' experience, our daily city bike output is up to 1000, and daily electrical bicycle output is 200, which can satisfy the large orders requirements.
The front fork and front wheel assembling.
The chains and chain cover assembling.
The handlebar and saddle assembling.
To ensure a 100% pass rate, we especially set the detection and package zone for the finished products. The detection details include 28 parts, mainly involve the spraying quality (right color, flat surface, no scratches, no chromatic aberration), the model and the size (right size, right models of the motor, the fork and the manual transmission), the exterior parts installation (appropriate installation of the front and back wheels, the crankset, and the chain cover), the accessories, the label, the frame, the panel, etc.
The carbon fiber frame testing
Since product quality is our highest priority, this room is particularly set for frame testing. The picture shows a sketch of the fatigue test with horizontal force, the process of which will last for 24 hours.
The frame pedal force fatigue testing. The frame disc fatigue testing.
The front fork fatigue testing. The front fork and frame impact testing.
The electrical bicycle testing
We use an electric-vehicle tester to see whether the motor functions well. The large current cycle life detector is employed here to test the charge and discharge performance of the battery.