Why 10-Station Automatic Gas-Filling & Sealing Machine Elevates Automotive High-Voltage Relay Production Quality?

Introduction: The Hidden Bottleneck in Custom High-Voltage Relay Manufacturing

In new energy vehicle and automotive electrical system manufacturing, high-voltage relays act as core safety and control components. Their sealing tightness, internal vacuum stability, and gas filling uniformity directly determine the relay’s service life, insulation performance, and operational safety in extreme vehicle working conditions.

For most auto parts component factories and custom relay manufacturers, low-efficiency single-station processing equipment, unstable vacuum pressure rise data, and inconsistent manual operation standards have long been key pain points. These problems easily lead to high product rejection rates, unstable batch quality, and restricted production capacity, which seriously affect product delivery and market competitiveness.

As a professional original manufacturer of autoparts test equipment and automotive component production equipment, HeJin has deeply targeted the industry’s mass production pain points. We independently developed the 10-Station Automatic Gas-Filling & Sealing Machine for custom high-voltage relays, helping manufacturing enterprises achieve efficient, standardized, and high-precision relay batch production.

Why Traditional Relay Gas Filling and Sealing Equipment Cannot Meet Modern Production Standards

Most traditional relay processing equipment on the market adopts a single-station or simple multi-station serial working mode, which has obvious limitations in actual industrial production:

First, the production efficiency is low. Single-station equipment can only complete vacuum pumping, gas filling and sealing procedures one by one. The loading and unloading process will force the equipment to stop running, resulting in a large number of idle production time and unable to support large-batch order delivery.

Second, the product quality consistency is poor. Traditional equipment has unstable vacuum system parameters, slow pumping speed, and unqualified pressure rise holding performance. Long-term operation is prone to vacuum attenuation, leading to unqualified relay sealing performance and frequent leakage problems in subsequent helium leak detection tests.

Third, the degree of automation is low. Most devices rely heavily on manual operation, with inconsistent operation standards. Different workers’ operating habits will lead to differences in relay gas filling volume and sealing effect, making batch quality difficult to control.

Fourth, the compatibility is weak. Traditional equipment cannot be perfectly matched with the mainstream helium leak detection process in the industry, requiring enterprises to carry out secondary modification, increasing production costs and equipment investment cycles.

Core Advantages of HeJin 10-Station Relay Gas Filling & Sealing Solution

Different from ordinary peer equipment, our 10-station high-voltage relay automatic gas-filling and sealing machine is designed for automotive custom relay mass production scenarios. It adopts a dual-group alternating working structure, which completely subverts the traditional serial production mode and solves the pain points of low efficiency and unstable quality in the industry.

1. Dual-Group Alternating Working Mode, Zero Idle Production

The equipment is equipped with 10 working stations, divided into two independent working groups of 5 stations each. During operation, one group automatically completes vacuum pumping, precise gas filling and pressure holding sealing procedures, while the other group synchronously completes workpiece clamping, loading and unloading operations. The two groups work alternately without interfering with each other, realizing uninterrupted cycle production. The hourly production efficiency is as high as 250PCS, which effectively doubles the production capacity compared with traditional multi-station equipment.

2. High-Precision Vacuum System, Strictly Control Batch Sealing Quality

Based on industrial-grade vacuum design standards, the equipment’s main pipeline and gas-charging port have excellent vacuum performance. The ultimate vacuum of both the main pipeline and the gas-charging port can reach 5*10⁻⁴ Pa. The gas-charging port can quickly drop from positive pressure to 25 Pa within 28 seconds, with fast pumping speed and stable dynamic performance.

In terms of pressure holding and pressure rise detection, the equipment has passed strict factory testing: after the main pipeline is pumped to the limit vacuum and kept for 24 hours, the vacuum degree is still less than 5 Pa; after the gas-charging port is held for 20 minutes, the vacuum degree is stably controlled within 50 Pa. All indexes meet the high-standard sealing requirements of automotive high-voltage relays, and perfectly match the industry’s helium leak detection standard (leak rate ＜1*10⁻⁷ Pa·m³/s), ensuring zero leakage of batch products.

3. Full Automatic PLC Intelligent Control, Reduce Manual Errors

Equipped with industrial touch screen HMI and independent PLC control system, the equipment realizes one-key automatic operation of the whole process from vacuum pumping, gas filling, pressure holding to sealing. It supports multi-specification product recipe storage, which can quickly switch parameters according to different custom high-voltage relay models, avoiding parameter adjustment errors caused by manual operation.

At the same time, the equipment has built-in fault alarm and operation log recording functions, which can track the production status of each station in real time, provide complete data support for production quality traceability, and meet the standardized production management requirements of modern auto parts factories.

Compliance with International Standards, Adapt to Global Automotive Component Manufacturing

As professional autoparts test and production equipment, our relay gas filling and sealing machine is designed and manufactured in strict accordance with international industry standards, covering product safety, quality management and component manufacturing specifications:

• IEC 61810-1: Comply with general safety and performance requirements for electromechanical relays, ensuring the assembly and sealing quality of high-voltage relays
• ISO 16232: Follow automotive component cleanliness standards to control the internal cleanliness of the relay sealing cavity and avoid impurity-induced leakage
• IEC 60664-1: Meet low-voltage system insulation coordination standards, ensuring the electrical safety of equipment workshop operation
• ISO 9001: The whole process of R&D, production and factory inspection is in line with international quality management system standards

All equipment parameters are standardized and unified, which can perfectly adapt to the production and testing standards of automotive parts manufacturers in Europe, America, Southeast Asia and other global markets, helping customers’ products pass international quality inspections smoothly.

HeJin Source Manufacturer Strength, Beyond Equipment Supply

Most equipment suppliers in the market only focus on hardware sales, lacking in-depth understanding of automotive relay production processes and after-sales technical support capabilities. As a direct source manufacturer with independent R&D, production and manufacturing capabilities, HeJin’s core advantage lies in providing one-stop production and testing solutions for customers.

In the pre-sales stage, our professional engineering team will conduct in-depth communication according to customers’ custom relay specifications, workshop layout and production capacity goals, provide targeted equipment selection and process optimization suggestions, and avoid equipment mismatch and resource waste.

In the production and factory inspection stage, all equipment will complete full-function vacuum test, pressure rise detection and efficiency calibration in the factory, and only be delivered after all indexes are up to standard.

In the after-sales stage, we provide complete equipment operation manuals, electrical drawings and spare parts lists, support remote fault diagnosis, video guidance maintenance and overseas technical guidance services, and long-term supply of core wearing parts, ensuring the long-term stable operation of customer production lines.

Application Scenarios & Market Value

This 10-station automatic gas-filling and sealing machine is specially customized forcustom high-voltage relays, widely used in new energy vehicle power control systems, automotive electrical components, industrial high-voltage control relay manufacturing and other fields.

For relay manufacturing enterprises, the equipment can effectively reduce product rejection rates, improve batch production consistency, save manual labor costs, and greatly improve production line efficiency and product qualification rate. Stable product quality can help enterprises pass strict supplier audits of mainstream automobile manufacturers, expand global market orders, and enhance core market competitiveness.

Final Conclusion

With the continuous upgrading of new energy vehicle safety standards, the quality requirements for automotive high-voltage relays are becoming increasingly stringent. Traditional low-efficiency and unstable production equipment can no longer adapt to the high-standard and large-batch production needs of the industry.

HeJin’s 10-Station Automatic Gas-Filling & Sealing Machine breaks through the bottleneck of traditional equipment, with efficient alternating production mode, high-precision vacuum sealing performance and intelligent automatic control system, providing reliable core equipment support for global auto parts and relay manufacturers. As a professional manufacturer of autoparts test equipment, we always focus on customer production pain points, rely on independent R&D strength and perfect after-sales system, and create maximum value for customers’ production and development.

Frequently Asked Questions

Q1: What types of relays is this equipment suitable for?

A: It is specially designed for custom high-voltage relays, widely applicable to new energy automotive high-voltage control relays and industrial automotive electrical component relays.

Q2: Can the equipment adapt to multi-model relay production?

A: Yes. The PLC system supports storing multiple production recipes, which can quickly switch parameters to meet the processing needs of different specifications of high-voltage relays.

Q3: Is the equipment compatible with helium leak detection process?

A: Completely compatible. The equipment reserves a matching interface for spray helium leak detection, which can be seamlessly connected with the industry’s mainstream leak detection process to verify relay sealing performance.

Q4: What is the advantage of your equipment compared with peer products?

A: We are a source manufacturer with independent R&D and production capabilities. The dual-group 10-station alternating structure realizes zero idle production, and all vacuum and pressure rise parameters are strictly calibrated. At the same time, we provide professional pre-sales process customization and full-cycle after-sales technical support, which is far superior to trading companies and assembly manufacturers.