How to Control Refrigerant Filling Quantity Automatically
Introduction
Controlling refrigerant filling quantity automatically is a critical requirement in automotive assembly lines, where incorrect fluid volumes can lead to system inefficiency, component damage, or warranty claims. Manual filling methods often introduce variability, making it difficult to maintain consistent liquid levels across production units. This article explains how automated vacuum filling systems manage refrigerant and coolant filling quantity with precision, covering the working principle, key features, and practical applications. The focus is on PLC-controlled equipment that integrates vacuum evacuation, leak testing, pressure filling, and back suction into a single automated cycle.
Product Overview
The Antifreeze Vacuum Filling Machine is designed for automated coolant and antifreeze filling on automotive production and assembly lines. It uses a PLC-controlled system to automate the complete filling process, from vacuum evacuation to final liquid level stabilization. The machine is suitable for applications requiring precise filling volumes and stable liquid levels, particularly in powertrain manufacturing, new energy vehicle assembly, and general automotive fluid filling operations.
This equipment addresses common challenges in fluid filling, such as inconsistent fill volumes, post-fill level drops, and undetected leaks. By integrating multiple process steps into one automated cycle, it reduces manual intervention and improves process repeatability.
Working Principle
The automatic control of refrigerant filling quantity is achieved through a sequence of controlled steps managed by the PLC system:
Vacuum Evacuation: The system first removes air and moisture from the vehicle's cooling circuit by creating a vacuum. This step is essential for preventing air pockets that could affect filling accuracy.
Leak Testing: Under vacuum and pressure conditions, the system performs leak testing to confirm circuit tightness. A negative pressure leak rate of ≤0.5 mbar / 60 s and positive pressure leakage of<1.4 g/year are used as reference criteria.
Secondary Vacuum: After confirming tightness, a secondary vacuum is created to prepare the circuit for filling.
Pressure Filling: Coolant is introduced under controlled pressure (1–4 bar) until the filling pressure reaches equilibrium.
Venting and Back Suction: The system automatically vents to atmospheric pressure and performs back suction to remove excess coolant. This ensures the specified liquid level is achieved and prevents the coolant level from dropping after filling.
This integrated cycle allows precise control of filling quantity, with a filling precision of ±0.5% and liquid level accuracy of ±2 mm.
Key Features
PLC-Controlled Automation: The entire filling process is automated, reducing manual errors and improving consistency.
Integrated Leak Testing: Vacuum and pressure leak tests are performed within the same cycle, ensuring system integrity before filling.
Back Suction for Level Stability: Excess coolant is removed to achieve the target liquid level and prevent post-fill drops.
Wide Filling Volume Range: Supports filling volumes from 1 to 400 L, suitable for various vehicle and component sizes.
High Filling Speed: Maximum filling speed of 60 L/min supports efficient production line integration.
Precise Measurement: Filling precision of ±0.5% and liquid level accuracy of ±2 mm ensure reliable fill quantity control.
Customizable Dimensions: Equipment dimensions of 1800 × 1000 × 800 mm can be customized to fit specific line layouts.
Applications
The Antifreeze Vacuum Filling Machine is suitable for automated coolant and antifreeze filling in:
Automotive manufacturing and assembly lines
Powertrain manufacturing
New energy vehicle production
Automotive component filling
Intelligent factory automation systems
It is particularly useful in applications where precise filling quantity and stable liquid levels are required to meet quality and performance standards.
Benefits
Improved Filling Accuracy: Automated control ensures consistent filling quantities, reducing variability.
Stable Liquid Level: Back suction prevents level drops after filling, maintaining specified levels.
Integrated Leak Detection: Early detection of leaks prevents fluid loss and potential system failures.
Process Consistency: PLC control standardizes the filling cycle across production units.
Reduced Manual Intervention: Automation minimizes operator involvement, lowering labor costs and human error.
Production Integration: The system can be integrated into existing assembly lines for seamless operation.
Why Choose KINMARK
KINMARK (Jinan Zhongzheng Jinma Technology Co., Ltd.) has been developing and manufacturing marking and traceability, servo press, fluid filling, and robot automation systems since 1996. The company is a Shandong Province "Gazelle" and "Specialized and Sophisticated" enterprise, with offices and service centers in major Chinese cities including Shanghai, Beijing, Guangzhou, Changchun, Wuhan, and Chongqing.
KINMARK has established long-term cooperation with automotive manufacturers such as Mercedes-Benz, BMW, Toyota, Volkswagen, Tesla, GM, Nissan, FAW Hongqi, GAC, Changan Automobile, BYD, Great Wall Motor, Geely, Chery, XPeng, and NIO. The company also provides automation solutions to world-renowned enterprises like Bosch, BorgWarner, Gree, CRRC, Meritor, and AGCO.
The Antifreeze Vacuum Filling Machine reflects KINMARK's focus on intelligent factory automation, integrating PLC control, vacuum technology, and precise measurement to meet the demands of modern automotive fluid filling. Explore KINMARK's fluid filling solutions for related industrial applications.
Frequently Asked Questions
How does the machine ensure accurate refrigerant filling quantity?
The machine uses a PLC-controlled sequence that includes vacuum evacuation, leak testing, pressure filling, and back suction. Filling precision is ±0.5%, and liquid level accuracy is ±2 mm, ensuring consistent fill quantities.
What is the purpose of back suction in the filling process?
Back suction removes excess coolant after filling to achieve the specified liquid level and prevent the coolant level from dropping after the filling process is complete.
Can this machine be integrated into an existing assembly line?
Yes, the machine is designed for automated coolant and antifreeze filling on automotive production and assembly lines. Its dimensions (1800 × 1000 × 800 mm) are customizable to fit specific line layouts.
What types of fluids can be filled using this equipment?
The machine is designed for filling antifreeze and coolant. The filling medium specified is antifreeze / coolant.
What is the maximum filling speed and volume?
The maximum filling speed is 60 L/min, and the filling volume range is 1–400 L, suitable for a wide range of automotive applications.
Conclusion
Automatically controlling refrigerant filling quantity is essential for maintaining production quality and vehicle performance. The Antifreeze Vacuum Filling Machine integrates vacuum evacuation, leak testing, pressure filling, and back suction into a single PLC-controlled cycle, delivering filling precision of ±0.5% and liquid level accuracy of ±2 mm. With its ability to handle filling volumes from 1 to 400 L at speeds up to 60 L/min, this system supports efficient and reliable fluid filling on automotive assembly lines. For manufacturers seeking to improve filling accuracy and process consistency, automated vacuum filling technology offers a practical solution.
If you're interested in any of the equipment mentioned in this article, feel free to contact our sales engineers for detailed product information and customized technical solutions.