350-800mm Core Height | Fin Forming + Core Assembling Fully Automatic Production Line | Single-Row Core Full-Automation System for Automotive Radiators
1. Product Overview

This production line integrates the GS-200 single-channel fin forming machine with an automatic core assembling machine, enabling fully automated core assembly from aluminum foil coils to finished cores. The fin former runs at a stable speed of 180m/min (max 200m/min), while the automatic core assembler handles tube magazine feeding, tube-fin matrix arrangement, core leveling/compressing, and header plate pressing/expanding in a complete workflow. Typical applications include high-volume automated production of passenger car and commercial vehicle radiator cores.

2. Industry Challenges & Root Cause Analysis

Difficult to balance fin forming speed and accuracy:Fin height consistency fluctuates at high speeds, and cut-off precision is hard to control. Root cause: lack of high-precision servo coordination between tension control and counting/cutting.

Low automation in tube-fin assembly:Tube and fin arrangement relies on manual placement – inefficient and inconsistent. Root cause: tube magazine feeding, tube separation, and fin introduction lack synchronized linkage.

Insufficient core assembly precision:Uneven tube ends lead to poor header plate expansion or tube deformation. Root cause: insufficient timing optimization among leveling, flattening, clamping, and pressing actions.

Disconnected process flow:Fin former and core assembler operate independently, requiring manual transfer between machines. Root cause: lack of interlock signals and automatic material docking design.

3. Solution

3.1 High-Speed Precision Fin Forming Machine (GS-200)

• Max speed 200m/min, stable speed 180m/min, cutting frequency ≥100 cuts/min, cutting accuracy ±0 peak (cut exactly at peak)

• Tension sensor with servo feed ensures fin height consistency across full speed range; fin height adjustable within allowable range

• Counting worm and cut-off servo precisely coordinate – each fin strip has zero peak-count error, stopping uniformly at peak position

• Carbide rolls with grinding + mirror polishing – service life ≥3 billion peaks (non-clad aluminum foil) for extended continuous operation

• HMI stores 50 tooling specifications – one-touch recipe recall for fast changeover

3.2 Automatic Core Assembling Machine

• Bundled tubes loaded directly into tube magazine – no plastic trays required; binding paper automatically removed; star wheel precisely distributes tubes; worm mechanism arranges tubes sequentially

• Fin feeding mechanism receives finished fins from the former, automatically inserting them into set gaps between tubes

• Tube-fin matrix transferred as a complete unit to core support platform; bridge platform ensures level docking without step difference

• Leveling, flattening, clamping, and header pressing/expanding in coordinated sequence – cycle time ≤40s

• Servo-driven with motion controller – operating parameters storable for fast changeover

3.3 Full-Line Integration

• Fin former provides start/stop and fault signal ports for communication with core assembler – automatic material docking eliminates manual handling between processes

4. Technical Specifications (Full Line)

5. Selection Guide

5.1 Recommended Scenarios

• High-volume automated production of automotive radiator cores

• Production upgrades seeking faster fin forming speed, higher precision, and reduced labor dependence

• Customers requiring seamless automated interfacing between fin forming and core assembly

5.2 Key Selection Considerations

1. Product size range: Verify core height (350–800mm), width (100–700mm), thickness (16–32mm) are within coverage

2. Fin parameters: Confirm fin height (5–8mm) and aluminum foil thickness (0.05–0.15mm) are compatible

3. Fin width: Verify required fin width is within customizable range of 12–56mm

4. Capacity: Line cycle ≤40s/unit – calculate against daily output requirements

6. FAQ

Q1: What is the service life of the forming rolls?

A: The rolls are made of carbide with a service life of ≥3 billion peaks (non-clad aluminum foil) and ≥2 billion peaks (clad foil). One-year warranty period.

Q2: How are the fin former and core assembler connected?

A: The fin former provides start/stop and fault signal ports for interlock communication. Finished fins are delivered directly to the assembler's fin feeding mechanism via a turnover and upright conveying device.

Q3: Is changeover convenient?

A: The fin former HMI stores specifications for 50 tooling sets – one-touch recall. The core assembler uses quick-change tooling with storable key position parameters – overall changeover is fast and efficient.

Q4: How is cut-off accuracy ensured?

A: A servo-controlled counting worm adjusts in real-time based on roll speed and material accumulation, precisely positioning each fin strip with zero peak-count error – cut consistently at the peak.

Q5: Can the equipment connect to MES systems?

A: Equipped with MITSUBISHI motion controller and PLC supporting data acquisition interfaces – MES integration available upon request.

7. Why Choose Wuxi Wondery

• Premium components: MITSUBISHI motion controller & servos, AIRTAC pneumatics, OMRON sensors, WEINVIEW HMI, SCHNEIDER buttons – long-term reliability

• High-speed fin forming: 180m/min stable speed, carbide rolls with long life, high precision, and fast changeover

• Fully automatic core assembly: Tube feeding, separation, fin insertion, leveling, flattening, and header pressing/expanding – all automated

• Full-line integration: Fin former and core assembler automatically docked – no manual transfer between processes

• Full support: User manual, inspection report, and remote diagnostics available