High-speed jumper plug-in solution for global home appliance giant Gree Electric Appliances

• 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.

• 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.

• 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):

"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.