The latest generation dishwashers have little to do with those of just a few years back. They now have water-saving systems; in case of leaks, the water flow is automatically stopped and the consumption is regulated depending on the load. The Fagor AIS range of dishwashers offer, moreover, the possibility of converting into domotic devices. The very process of manufacturing these dishwashers is also innovative.
The tub of these dishwashers is shaped in a specialised stamping machine which uses a technology known as hydroforming to shape the ub, i.e. the steel plate is shaped under pressure of water. The inside of this steel part, surrounded and held by the walls of the machine, is subjected to high pressure water and merges from the machine in just half a minute. Under the enormous pressure the steel is shaped with ease to the desired form. The process is a high precision one as the steel plate forming the tub has a very small thickness, less than half a millimetre and, consequently, if too much pressure is applied at any point, the metal could break.
At a normal working pace, the machine is capable of producing 100 parts an hour. So that the pieces of steel plate do not pile up at the entrance, the work programme has to be co-ordinated with the robots that supply them. Using this hydroforming technology, a resistance of 800 kilograms per square centimetre is produced. Thus, the tubs are lighter than those manufactured previously but, moreover, they are stronger and more resistant.
The tubs are transferred to other machines to trim the sides and to perforate the orifices required for water inlet and drainage as well those required for the pump system and decalcification. The bending operation to shape the front part of the cube is carried out elsewhere, as is the welding of the supports for the basket trays and doors.
The tubs then are transferred to the furnace prior to which each part is covered with asphalt and this coating-baking operation is repeated twice. The asphalt provides acoustic insulation during the operation of the dishwasher.
Now the real assembly process can begin, starting with the base of the dishwasher, onto which the heating element, the wash pump motor, the drainage system, the water distributor and the other parts are fitted. Although more controls are carried out later, once these parts are installed, tests are carried out to check for possible leaks.
One of the most notable characteristics of this model of Fagor dishwasher is the fact that it consumes less water than its predecessors. A sensor located in the washing pump is the main reason for this saving, involving a turbidity detector: if the water is deemed sufficiently clean, this is reused; if not, it is drained off and fresh water taken in. The detector has been named an ecosensor.
The new model of dishwasher has other saving systems also, the load detector, for example, which calculates the load introduced and, depending on this, automatically regulates the consumption. Washing with minimum use of washing-up liquid, rapid washes, double wash for the dirtiest items and heavy or light wash modes are other options with this dishwasher.
We continue along the assembly line: the base supports, the hydraulic equipment, the water intake system and other systems, such as the electrical system, are fitted. Subsequently, the door springs, electronic control circuit, the ventilator and condenser are fitted. This dishwasher has a system of ventilation drying such that, when the door opens, water vapour is not expelled.
On fitting the tub to the base of the dishwasher, the hoses, sprayer, locking device, door interior and control panel are installed and also checks are carried out to ensure the electrical safety of the machine.
The assembly of the dishwasher is coming to an end, bit by bit. But, before continuing, other checks are undertaken: operating cycle tests and leakage checks are carried out on each and every machine with the aim of ensuring hat everything works correctly. These checks are primarily carried out visually and then checked with the help of a computer.
The computer provides information about time and intensity, i.e. how much work each dishwasher does in a certain time. If some defect or other is detected, if possible it is remedied on the spot; if not, it is sent to the point along the assembly line where the error is deemed to have occurred for its repair. Apart from these checks, a statistical, quality control is carried out.
Once permission is obtained to continue, the machines have their external panels and top fitted at the packing area. Finally, the dishwashers are packed in boxes and stacked in the store from where they are dispatched to the sales outlets.
From Basque Research