1. Frame & Layout
The entire line frame is constructed with high-strength 4040 / 4080 aluminum alloy profiles adopting a modular design. Its vibration resistance and structural rigidity comply with Chinese GB national standards. Flexible layouts including U-shaped, linear and customized closed-loop layouts are all supported.
Since smart toilets incorporate precision electronic modules, the worktop adopts double-layer anti-static protection:
The bottom layer is covered with 5 mm high-density anti-static rubber sheet (surface resistance: 10⁶ ~ 10⁹ Ω); partial areas on the top surface are additionally fitted with anti-static PU foam pads. This structure effectively absorbs impact energy generated during the transportation of ceramic housings and blocks static electricity interference to PCB circuit boards.
An integrated dustproof & explosion-proof LED lighting system is installed overhead, with illuminance ≥ 800 Lux, ensuring precise alignment of waterway and electrical connectors.
2. Conveying System
The core transmission unit adopts 3.0-speed heavy-duty double-speed chains paired with precision curved roller bearings to bear the heavy load of empty ceramic smart toilet housings (typically 35–50 kg each). Driving power is provided by heavy-duty geared motors equipped with vector inverters for stepless speed regulation ranging from 0 to 10 m/min.
Hydraulic lifting platforms or lifting transferring mechanisms are installed at both inlet and outlet ends of the line, enabling smooth transfer of toilet bases between workstations with different elevation heights.
3. Ergonomic Assistance System (Heavy-Duty Load Handling System)
Integrated heavy-duty pneumatic balance cranes (power-assisted manipulators) are longitudinally arranged along the production line, specially designed for one-piece smart toilet housings (40–60 kg) and complex electric control boxes:
- Rated lifting capacity: 80 kg – 150 kg (double-joint structure)
- Operation mode: Fully pneumatic servo control with dual working modes: Floating Mode & Floating + Power-Assist Mode. Operators only need to apply minimal pulling force to flip, laterally shift the ceramic housing and accurately mate it with the base. This eliminates efficiency bottlenecks and occupational injury hazards caused by frequent heavy lifting operations.
4. Workstation Utilities & Facilities
- Heavy-duty tool hanging panels: Fabricated from 2.0 mm thickened cold-rolled steel plate, with a bearing capacity ≥ 10 kg, compatible with heavy-duty electric screwdrivers, torque wrenches and manual hydraulic presses.
- Integrated air supply system: Each workstation is pre-equipped with high-flow quick couplings and air manifolds to meet instantaneous high air consumption demand for pneumatic wrenches, caulking guns and other pneumatic tools.
- Pipeline & cable management: Fully enclosed cable drag chains are arranged at the bottom, while stainless steel cable conduits are mounted on the upper part. Strong current cables, weak current wiring and air pipelines are spatially separated in three dimensions to prevent winding and entanglement.
5. Informatization & Error-Proofing (Andon & MES System)
10.4-inch industrial touch all-in-one PCs with IP65 protection grade are mounted above each workstation.
- BOM Matching: Scanning the barcode on each toilet unit enables the system to automatically retrieve the corresponding Bill of Materials (BOM) and 3D assembly instructions, for example distinguishing internal structural differences between instant-heating and storage-heating smart toilet models.
- Key Process Poka-Yoke Error Prevention: The system is embedded with Poka-Yoke logic control. For instance, the pallet cannot be released to the next workstation if no buckle locking signal is detected at the water pipe connection station, or if a qualified test report (leakage rate ＜ 0.05%) is not received from the air tightness tester at the safety inspection station.
- Real-Time Data Acquisition: The system continuously records operator ID, tightening torque curves and inspection results at critical stations (seat ring installation, main control board wiring, etc.), and uploads all data to the cloud database.
6. Tooling Fixtures
Fixtures are precision CNC machined from anti-static bakelite or molded nylon sheets.
- Positioning Reference: Locating pins are laid out according to rounded corners and mounting holes of the smart toilet ceramic base, adopting the universal mechanical positioning principle of one plane, two pins, with repetitive positioning accuracy of ±0.5 mm.
- Mistake-Proof Design: The fixture is equipped with buffer positions for toilet seat rings, temporary storage grooves for inlet water pipes and supporting feet for electric control boxes, preventing displacement or tipping of heavy components during circulation.
7. Safety Protection & Quality Control Interfaces
- Safety Safeguards: Safety light curtains (20 mm resolution) and pull-cord emergency stop switches are deployed along the whole line, connected to dual-channel safety relays. Sound insulation hoods are installed at workstations with noise exceeding 85 dB (such as air tightness test chambers).
- Integrated Comprehensive Testing Interface: Dedicated ports for comprehensive test chambers are reserved at the final assembly section, supporting three types of tests below:
- Air tightness test: Micro-pressure leak test for pipeline sealing inspection
- Electrical performance test: Withstand voltage, earthing resistance and leakage current testing
- Functional simulation test: Simulation and operation verification of core functions including flushing, warm air drying and seat heating
All test data (pressure curves, current waveforms, functional response time) are bound to the unit barcode to generate tamper-proof quality inspection reports, fully complying with Chinese national standards GB 25501 and CJ/T 194.
8. Core Technical Parameter Table
| Item |
Specification |
| Rated Load |
≥ 100 kg per workstation (custom heavy-load options available) |
| Conveying Speed |
1–10 m/min (variable frequency speed regulation for heavy loads) |
| Positioning Accuracy |
±0.5 mm |
| Main Control Unit |
PLC (Siemens / Omron) + Industrial PC |
| Communication Protocols |
Ethernet/IP, Modbus TCP, OPC UA |
| Power Supply |
AC 380V/50Hz, 3-phase 5-wire power system |
| Air Source |
Clean compressed air treated by air service units, 0.6–0.8 MPa |
Summary
This production line is a custom-built heavy-duty automated assembly platform exclusively developed for the smart toilet (electronic bidet toilet) industry. By upgrading load-bearing mechanical structures, equipping heavy-duty power-assisted lifting equipment and implementing rigorous Poka-Yoke error-proofing mechanisms, the line thoroughly addresses three core pain points prevailing in traditional smart toilet assembly: difficult heavy component handling, high water pipe connection error rates, and insufficient traceability for comprehensive quality inspection.
Custom non-standard design and turnkey delivery are available based on customers’ existing plant layouts and specific product types (instant-heating / storage-heating / entry-level smart toilets).
