Custom Affordable Reliable Scooters Manufacturers

What key processes can improve the service life of wheelchair scooters in factory warehouses?

Core material processing technology: laying the foundation for durability
The service life of factory warehouse wheelchairs is directly related to material properties. The optimization of the entire process from raw material screening to pretreatment is the core of improving the wear and corrosion resistance of products.
1. Alloying treatment of high-strength metal materials
Material selection and alloy ratio: Use aviation-grade aluminum alloy (such as 6061-T6) or high-strength stainless steel (304/316) as the main body of the frame, and add alloy elements such as magnesium and silicon to improve the strength and toughness of the material. For example, Suzhou Heins Medical Equipment Co., Ltd. strictly selects aluminum alloy profiles with a yield strength of ≥270MPa in the production of the frame of all-terrain affordable scooters to ensure that the frame is not easily deformed under complex road conditions.
Material aging treatment: Artificial aging (175℃×8 hours) of aluminum alloy components is performed to improve the hardness of the material by precipitating strengthening phases, reducing the risk of fatigue cracks in long-term use. This process can increase the hardness of the material by more than 30%, and is suitable for load-bearing parts (such as wheel brackets and seat frames).
2. Modification process of engineering plastic parts
Polymer material reinforcement: For plastic parts such as armrests and footrests, glass fiber (GF) or carbon fiber (CF) is used to reinforce polypropylene (PP) materials, and uniform blending is achieved through a twin-screw extruder, which increases the impact strength of the parts by 50% and extends the aging resistance by 2-3 years.
Weather resistance improvement: Add ultraviolet absorbers (such as benzotriazoles) and antioxidants (hindered phenols), control the melt temperature (220-240℃) during the injection molding process, avoid thermal degradation of the material, and ensure that the plastic parts will not show obvious cracking within 5 years when used outdoors.

Processing technology of key structural parts: improving the stability of mechanical properties
1. Optimization of precision welding process
Application of argon arc welding (TIG) and laser welding: Pulse argon arc welding is used for frame welding. By precisely controlling the welding current (80-120A) and pulse frequency (20-50Hz), the width of the heat affected zone (≤1mm) is reduced to avoid the decrease in the strength of the base material. For example, Suzhou Heins Medical Equipment Co., Ltd. uses laser welding at the folding joints of multi-functional factory warehouse wheelchairs. The weld strength can reach more than 90% of the parent material, ensuring that the folding structure will not crack after 100,000 cycles.
Post-weld stress relief: Stress relief annealing (200-250℃×2 hours) is performed on the welded parts, and the residual stress is reduced by furnace cooling to reduce the risk of fracture caused by stress concentration during long-term use.
2. Precision machining and assembly of parts
CNC machining precision control: CNC lathes are used to process key parts such as wheel axle holes and bearing installation positions, with dimensional tolerances controlled within ±0.05mm and surface roughness Ra≤1.6μm, ensuring reasonable bearing clearance and reducing operating noise and wear.
Interference fit process optimization: The seat shaft and other parts are heat-fitted (heating the sleeve to 80℃) to achieve interference assembly, and the interference is controlled at 0.03-0.05mm to avoid loosening and abnormal noise during long-term use.

Surface protection process: Enhanced resistance to environmental corrosion
1. Application of multi-layer coating system
Pretreatment process: Affordable scooters’ metal parts are pretreated by the three-step method of "degreasing-phosphating-passivation", and the thickness of the phosphating film is controlled at 2-3μm to improve the adhesion of the coating. For example, the frame of the lightweight folding reliable scooter is phosphated with zinc-nickel alloy, and there is no rust in the salt spray test (ASTM B117) for 500 hours.
Combination of electrophoretic coating and powder spraying: cathode electrophoresis is used for the bottom layer (film thickness 15-20μm), and weather-resistant powder coating (thickness 60-80μm) is sprayed on the surface to form a composite coating. This process can make the coating hardness reach more than 2H, and the scratch resistance is improved by 40%, which is suitable for outdoor all-terrain models.
2. Innovation of special protection process
Dacromet treatment: zinc-chromium coating process is used for standard parts such as screws and nuts, with a coating thickness of 3-5μm, and no white rust in the salt spray test for 1000 hours, which solves the hydrogen embrittlement problem of traditional electroplated parts and is suitable for humid environments (such as warehouse storage).
Nano ceramic coating: nano zirconium oxide ceramic coating (thickness 50-100nm) is sprayed on the surface of the wheel hub, and uniform film formation is achieved through the sol-gel method. The surface hardness can reach 9H, which reduces the scratches on the hub caused by gravel impact.

Process upgrade of key functional components: improve system reliability
1. Precision manufacturing of drive system
Gear grinding process of motor gearbox: Planetary gearbox is processed by CNC gear grinding machine, tooth surface roughness Ra≤0.8μm, meshing clearance is controlled at 0.02-0.04mm, reducing operating noise (≤65dB) and wear, ensuring motor life ≥1000 hours (continuous operation).
Insulation treatment of motor winding: Vacuum impregnation (VPI) process is adopted, solvent-free epoxy resin is used for impregnation, insulation grade reaches F grade (temperature resistance 155℃), avoiding winding short circuit in long-term operation.
2. Sealing process of brake system
Sealing treatment of hydraulic brake components: Brake cylinder adopts nitrile rubber (NBR) sealing ring, with hard chrome plating (thickness 8-10μm) on the surface, ensuring that the hydraulic system is leak-free in -20℃ to 60℃ environment, and the braking response time is ≤0.3 seconds.
Wear-resistant treatment of electromagnetic brakes: brake pads use semi-metal-based friction materials, with graphite and ceramic particles added, the friction coefficient is stable at 0.35-0.40, and the wear rate is ≤0.1mm/1000 braking times, which is suitable for frequent start-stop scenarios.

Assembly and testing process: ensure that the quality of the entire process is controllable
1. Automated assembly and torque control
Application of intelligent tightening system: key bolts (such as frame connection, motor fixation) use electric tightening guns, the torque accuracy is controlled at ±3%, and the data is recorded by scanning the code to achieve traceability of the assembly process. For example, a tightening error prevention system is introduced in the production line to ensure that the tightening torque of each screw meets the design requirements (such as M8 bolt torque 12-15N・m).
Lubrication process of joints: folding joints, wheel bearings and other parts use automatic grease injection machines to add silicone-based grease (dropping point ≥200℃), and the grease injection amount is controlled at 0.5-1g/point to reduce friction loss and extend the life of moving parts.
2. Full-project reliability testing
Simulated working condition test: The finished reliable scooter must pass a 6-hour continuous bump test (amplitude 50mm, frequency 2Hz), 1000 folding cycle tests, and a 30° slope climbing test to ensure that the structural parts are not loose or cracked.
Electrical safety and life test: The battery system undergoes 500 charge and discharge cycles (capacity retention rate ≥80%), and the controller runs continuously for 48 hours without failure in an environment of -10℃ to 40℃, in compliance with the IEC 60601 medical equipment safety standard.

Warehouse storage and maintenance process: Extend the service life during idle period
1. Warehouse environment control
Temperature and humidity management: The warehouse maintains a temperature of 15-25℃ and a humidity of ≤60% RH. Real-time monitoring is carried out through dehumidifiers and air conditioning systems to prevent metal parts from getting damp and rusting. Suzhou Heins Medical Equipment Co., Ltd. uses constant temperature and humidity storage in overseas warehouses (such as the European region) to keep the rust rate of inventory products less than 0.5% within half a year.
Dust-proof and anti-oxidation packaging: The whole reliable scooter is wrapped with PE moisture-proof film, and key metal parts (such as axles) are coated with anti-rust oil (NLGI level 2) and placed in vapor phase anti-rust bags (VCI), which are valid for up to 12 months.
2. Regular maintenance process
Battery activation and maintenance: Long-term storage of mobility scooters requires shallow charging and discharging every 3 months (charge to 80%, discharge to 50%) to avoid long-term storage of lithium batteries with full charge, resulting in capacity attenuation. The after-sales department of Suzhou Heins Medical Equipment Co., Ltd. uses intelligent charging cabinets to achieve batch maintenance.
Mechanical parts lubrication re-inspection: Secondary lubrication of the brake system and folding joints of inventory affordable scooters to replenish the grease lost due to volatilization to ensure that the performance of the products shipped out is as good as new.