Helping BYD Electronics achieve efficient PCBA component orchestration and precision automation
Published On: January 21, 2026
Customer Name: Gree Electric Appliances
Industry: Home Appliance Manufacturing / HVAC (Heating, Ventilation and Air Conditioning)
Application Products: Air Conditioning Main Control Board, Variable Frequency Control Module
Core Challenges: Improving PCB jumper insertion efficiency, reducing raw material waste, and achieving digital workshop management.
In expanding its variable frequency air conditioner production capacity, Gree faced bottlenecks in traditional jumper processing technology:
- Efficiency Bottleneck: The existing manual insertion method could not meet the cycle time requirement of thousands of times per minute.
- High Consistency Requirements: Variable frequency circuits have extremely high precision requirements for jumper span and insertion depth, making it difficult for manual operation to maintain long-term stability.
- Complex Material Management: A device was needed to directly convert coiled copper wire into finished jumpers, eliminating the pre-processing step.
For Gree's production environment, we delivered a high-performance horizontal jumper insertion machine series. Its core technological highlights include:
- Fully Automatic Forming and Cutting: The equipment directly connects to the coiled wire, completing cutting, bending, and insertion actions in real time, eliminating intermediate material waste.
- Dual-head high-speed operation: Utilizing a high-efficiency servo system, the insertion speed reaches 15,000-22,000 points/hour, and a single machine can replace 15-20 skilled workers.
- Visual correction system: Equipped with high-resolution CCD visual compensation, it automatically identifies PCB hole position deviations, ensuring an insertion success rate of over 99.9%.
- MES system integration: Designed for Gree's "lights-out factory" needs, the equipment supports real-time data uploads to monitor production progress, equipment utilization, and consumable reserves.
After actual operation on Gree's production line, the project achieved significant return on investment (ROI):
| Key Indicators | Before Implementation (Manual/Semi-automatic) | After Implementation (Our Equipment) | Improvement |
|---|---|---|---|
| Plug-in Speed | 800 points/hour/person | 20,000 points/hour | 25-fold increase |
| Material Loss Rate | 2.5% | < 0.1% | Significantly Reduced Wire Costs |
| Defective Repair Rate | 1.2% | < 0.05% | Improved Quality Stability |
| Changeover Time | 30 minutes or more | < 3 minutes (Digital Programming) | Enhanced Flexible Manufacturing Capabilities |
"The jumper insertion machine provided by your company demonstrated excellent stability under high-speed operation. It not only helped us solve the labor shortage during peak periods, but its precise molding process also significantly improved the soldering qualification rate of our PCB motherboards. It is an indispensable part of Gree's automated production line." — Head of Production Technology Department, Gree Electric Appliances
We focus on providing end-to-end automated plug-in solutions for global electronics manufacturing companies. In addition to patch cord machines, we also provide:
- Radial Inserter
- Odd-form Inserter
- full line integration and technical support.
