Production Analysis of the SOPUJIA TV Cart
As an essential accessory for conveniently transporting display devices in modern homes and offices, TV carts' production process integrates materials science, structural engineering, and precision manufacturing technologies. From design drawing to finished product, they undergo eight key steps, each of which adheres to strict quality standards to ensure product stability, safety, and practicality.
1. Pre-production Preparation
First, product design optimization takes place. Engineers use CAD software to create 3D structural diagrams based on target user requirements (e.g., lightweight for home use, heavy for commercial use). They focus on optimizing parameters such as the frame's load-bearing angle, universal wheel steering damping, and storage compartment spacing. They also simulate structural stresses at 1.2 times the rated load to mitigate metal fatigue risks. Next, supply chain screening takes place. The procurement department reviews the qualifications of steel suppliers, plastic component manufacturers, and hardware fabricators, prioritizing ISO9001-certified companies to ensure that raw materials comply with RoHS environmental standards. Finally, during production line commissioning, technicians adjust the parameters of equipment such as stamping machines, press brakes, and welding robots. For example, they calibrate steel stamping accuracy to ±0.1mm and stabilize welding current within the 180-220A range, laying the foundation for mass production.
II. Raw Material Procurement and Inspection
Raw material quality directly determines product performance, and this stage requires dual inspection standards. For the core material, cold-rolled steel (typically 1.2-2.0mm thick), yield strength (≥235MPa), tensile strength (≥370MPa), and surface flatness must be tested, and an ultrasonic flaw detector is used to detect internal cracks. Plastic components (such as storage panels and handle covers) undergo impact resistance testing (no cracking in temperatures between -30°C and 80°C) and environmental testing (formaldehyde emission ≤0.124mg/m³). Universal wheels undergo verification of their load-bearing capacity (≥50kg per wheel) and wear life (no damage after 5000 meters of continuous rolling). All raw materials must be accompanied by quality inspection reports. Unqualified materials will be returned immediately and strictly prohibited from entering the production process.
III. Core Component Manufacturing
(I) Metal Frame Processing
1. Steel Cutting: Cold-rolled steel sheets are cut to the designed dimensions using a CNC shearing machine. The cutting error is controlled within ±0.5mm to ensure subsequent processing accuracy.
1. Stamping: Dies are used to stamp the steel sheets to create the frame's connection holes, reinforcement ribs, and other structures. The die cutting edges must be regularly replaced during this step to prevent burrs.
1. Bending: A CNC press brake bends the steel sheets to a preset angle (commonly 90° or 135°) to form the frame's vertical and horizontal rails. After bending, the angle deviation must be checked to ensure it is ≤1°.
1. Welding and Assembly: Components are welded together using CO2 gas shielded welding. Key welds are inspected for flaws and polished after welding to ensure a smooth surface. (2) Plastic Component Manufacturing
Injection molding is primarily used, injecting molten ABS or PP plastic into a mold. After cooling, the molded components, such as the storage compartment and handle, are removed. During the injection molding process, the temperature (typically 220-260°C for ABS plastic), pressure, and cooling time must be controlled to prevent defects such as shrinkage cavities and deformation. After molding, the gate and flash must be removed.
(3) Caster Assembly
A caster wheel consists of a wheel body, bracket, bearing, and brake assembly. First, the bearing is installed in the wheel body, then assembled with the bracket, and finally, the brake assembly. After assembly, the caster wheel's rotational flexibility (rotational resistance ≤ 5N) and braking effectiveness must be tested to ensure no slippage under the rated load.
4. Surface Treatment
Surface treatment is required to enhance the product's corrosion resistance and aesthetics. There are two common methods for finishing metal frames: electrostatic spraying, which involves first degreasing, rust removal, and phosphating the frame, followed by spraying with epoxy resin powder. Finally, the frame is cured at 180-200°C. The coating thickness should be controlled at 60-80μm to ensure no sags or pinholes. Electroplating, primarily used for small hardware components (such as screws and hooks), uses electrolysis to form a chrome or zinc coating on the surface for improved rust resistance. Plastic components are polished or sprayed with oil to enhance their appearance and texture.
V. Overall Assembly Process
1. Component Pretreatment: Clean all components to be assembled to remove dust and oil.
1. Frame Assembly: Use screws to secure the welded metal frame to the reinforcements. Tighten the screws to the standard torque (usually 8-12 N·m) to prevent loosening.
1. Caster Installation: Bolt the casters to the mounting holes at the bottom of the frame, ensuring that all four wheels are aligned at the same height, with a tolerance of ≤1mm. 1. Installing Storage Shelves: Secure the plastic storage shelves or metal mesh shelves to the pre-set positions on the frame using clips or screws. Adjust the spacing between shelves to the designed value and ensure levelness (horizontal deviation ≤ 2mm).
1. Installing Accessories: Install handles, cable management racks, display mounting clamps, and other accessories according to the product configuration, ensuring they are securely installed and free of wobble.
VI. Finished Product Inspection
Inspection utilizes a combination of full inspection and spot checks. Full inspection items include: appearance inspection (no scratches, coating peeling, or component damage); dimensional inspection (overall height and width deviation ≤ 3mm); load-bearing test (load 1.2 times the rated weight, no structural deformation after 24 hours of rest); stability test (no tipping when tilted 30°); and mobility test (no lag or unusual noise when pushed). Random inspections include: salt spray testing (metal parts must be exposed to a neutral salt spray test for 48 hours to ensure no rust) and aging testing (plastic parts must be exposed to a high temperature of 70°C for 168 hours to ensure no cracking). The inspection rate must be no less than 3%. If unqualified products are found, the inspection scope must be expanded and the faulty link must be traced.
VII. Packaging and Warehousing Procedures
Products that pass inspection must be properly packaged. The inner layer is wrapped with PE film to prevent scratches; the middle layer is cushioned with foam board to prevent damage during transportation; and the outer layer is wrapped in a corrugated cardboard box. Inside the box are placed the product manual and an installation tool kit (screws and wrenches). After packaging, the outer box is labeled with information such as the product model, specifications, production date, and load rating. Products are then stored by batch in the finished product warehouse. The warehouse must be dry and well-ventilated (humidity ≤ 60%, temperature 5-30°C). Inventory records must be maintained to ensure product traceability.
VIII. Quality Control During Production
To ensure product consistency, strict quality control measures must be implemented throughout the entire production process. The workshop employs dedicated quality inspectors to conduct inspections of each process, recording key parameters (such as welding current and spray temperature). The MES production management system monitors production progress and quality data in real time, automatically alerting employees when anomalies occur. Employees undergo regular skills training, and only those who pass the assessment can resume their positions. Quarterly production process reviews are conducted, optimizing production processes based on market feedback and test data to continuously improve product quality.
Through this standardized and refined production process, every step of the TV cart production process, from raw materials to finished product, is effectively controlled. The result is a high-quality product that combines practicality, safety, and durability, meeting users' needs for convenient display device mobility in diverse scenarios.
