Production of Consumer Goods

Key Technologies for Consumer Goods Production

Molding and stamping shop	Assembly and test shop

In 1990 RSC Energia after S.P. Korolev started manufacturing of household electric appliances.
There are four manufacturing shops occuping an area of more than 29.000 m².
The number of the employees is some 600 people.
The manufacturing plant is fitted with high-precision and high-performance equipment made in Russia and abroad.

Plastic Moulding Under Pressure

There is a plastic molding shop on the territory of our enterprise.

A 200 m² plastic molding shop is equipped with 35 automatic molding machines (AMM), which produce parts by pressure molding method from thermoplastic polymeric materials. The installed AMMs made by NISSE (Japan) and DEMAG (Germany) with clamping force varying from 20 to 660 tons and injection volume from 18 to 2800 cm³ allow to manufacture a wide range of parts up to 3 kg by mass.

More than 15 types of thermoplastic polymeric materials are processed into finished products.

Most of the AMMs are fitted with the extra equipment to support feedstock preparation and feeding, production control, takeoff and transportation of products. All this makes it possible to manufacture parts in a fully automatic mode.

Also the shop can manufacture products from thermosetting polymeric materials using automatic molding machines for thermosetting materials (NISSEI, Japan) with clamping force of 120 tons and a 314 cm³ injection volume.

The shop is currently manufacturing completing items for vacuum cleaners, food processors, electric mixers, water purification filters and the like; there are altogether more than 200 types of parts.

Sheet Forming

Sheet forming is equipped with:

• High-performance 8-position automatic presses with force of 320 and 1000 tf, deep drawing of parts (diameter up to 200 mm) from a roll of tape up to 400 mm wide, sheets and strips;
• High-speed automatic press "OHTSUKA HE-100" for simultaneous blanking of rotor and stator core plates, piled assembly of rotor and stator cores, with an automatic transportation line and separate packing of rotor and stator cores;
• High-performance automatic presses "AIDA" with 35, 60, 85, 110 tf force and uncoiling, straightening devices for sheet forming of parts from sheet and roll metal (with S = 0,25 - 2,0 mm) in an automatic and semi-automatic mode;
• Multipurpose crank presses with a 500-tf force and table measuring 1400x2400 and 1800x3000 mm;
• Multipurpose 1 and 2 upright presses and 1- and 2- crank presses with force of 6,3; 16; 25; 40; 63; 100; 160 tf;
• Hydraulic presses with a 160-tf force.

Machining and Manufacture of Cutters

Machining is equipped with:

• rapid production single-bar and six-spindle automatic turning lengthwise lathes for parts up to 160 mm long and in diameter up to 16 and 30 mm respectively of the bar 3 m long;
• centerless grinding machines with the grinding wheel diameter of 400 mm and automatic and manual feed of parts;
• profile-burnishing two-roll machines with the force of 6.3 and 14 tf and automatic and manual feed of parts.

Cutters Manufacturing Area

It comprises the home-produced and import equipment including the cutter stamping presses for the food processor and mixer of stainless steels S = 0.5 -1.2 mm with a high wear and corrosive resistance, the parts degreasing line, heat-treatment furnaces, tumbling equipment for deburring and scaling-off, the todedge grinding machines and the part surface electropolishing line.

Types of cutters produced:

Commutator Motor Mamufacturing Procedure

The commutator motor assembly is accommodated in a shop of the total area of 6000 m² and consists of the commutator manufacturing area; the rotator, stator, ASU and motor assembly lines.

The commutator manufacturing area works on the closed cycle, namely from manufacturing bars to the off-the-shelf commutator. Presently two types of commutators are mass produced: 18-bar and 22-bar commutators. In the very near future the manufacture of 24-bar commutators will be mastered. The commutation power of the produced commutators is up to 1700 W, the rotation frequency is up to 35000 rev./min. The Japan-made unique equipment allows to manufacture 1000 commutators of each type per shift.

The automatic production line of rotors of the ODAWARA company (Japan) consists of 26 units integrated into a unified transport system; three rotor modifications are made using it.

The automatic mode line provides the full assembly, protective varnish impregnation, machining, balancing and testing of the engine rotors.
The line capacity is 1000 rotors per shift. The stator production line consists of the belt conveyor and 7 units of the Japan-made equipment; 5 stator modifications are made using them. The line capacity is 1000 stators per shift.

The air suction unit (ASU) production line consists of the belt conveyor and 11 Japan-made semiautomatic machines integrated into a unified transport system. In this line two types of ASU of the rated power of 1000 and 1300 W are produced.
Each ASU passes running-in and testing in the automatic control line. The line capacity is 1000 ASU per shift.

The motor production line consists of the belt conveyor and 8 Japan-made semiautomatic machines integrated into a unified transport system.
Two types of motors are produced in this line.
Each motor passes break-in and testing in the automatic control line. The line capacity is 1000 motors per shift.

Assembly Line Work

Consumer goods manufacturing plant is fitted with the assembly equipment containing band and apron conveyors with pneumatic - and electric power supply for operating the tool in use as well as built - in equipment to control electronically parameters of products to be assembled. Semiautomatic machines involved in the assembly process ensure high quality of finished products.

Food processor assembly line

Vacuum cleaner assembly line

Other Technologies

Tampon printing.

Tampon printing is used to apply logos and painted drawings to the bodies of household electric appliances. Tampon printing is one of the latest technologies in this area. Tampon printing is conducted by means of four-color ink pneumatic machine V130/130 DUO (TAMPOPRINT, Germany) with a closed inking system, which was custom-made and allows to apply tampon printing to large-size parts. As a result of adopting this technology, design of the household appliances has considerably improved.

Ultrasonic welding

Ultrasonic welding (USW) is widely used in consumer goods production.

The welding process lasts from fractions of a second (on small parts) to 3 seconds (on large - size parts). With USW no bulges characteristic of the assembly using solvents or adhesives are generated. The surfaces resulting from this welding are characterized by unique surface finish. As ultrasound heating proceeds only within the surfaces coming in contact with each other, the remaining parts are not subject to deformation during welding.

For welding the use is made of the Japan-made USW installation SONOPET 1500B/P45A.

Brush and mop manufacture

Brushes manufacturing area incorporates the following Italy-made installations (BORGHI company):

- Fiber-cutting machine
- Machine for brush and mop production
- Brush-cutting machine
The equipment like that allows to produce brushes and mops within a wide range of sizes and shapes (100x300 mm) from plastic or wooden blocks sewn across by vegetable, animal and synthetic fibers. Fiber packing at the base of brush is carried out under numerical program control of the machine, which makes it possible to provide quick readjustment of the equipment from one model to other model.

Extrusion

The plastic molding shop houses the manufacturing area designed to produce by extrusion corrugated hoses for different models of vacuum cleaners, as well as spray hoses for gardens and vegetable gardens. The existing Italy-made equipment OLMAS (extruder and corrugating machine) enables manufacture of corrugated hoses from thermoplastic polymeric materials based upon PVA, PVC, etc., as well as sanitary-engineering crinkled hoses of any length, with an outer diameter varying from 20 to 42 mm.