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Project Background
With the rapid growth of the new energy vehicle industry, the Vehicle Control Unit (VCU) – as the core component for vehicle power and safety control – is subject to ever‑increasing demands in terms of production capacity, precision, and reliability. Traditional manual production methods – characterised by low efficiency, poor accuracy, difficult traceability, and multiple quality risks – are no longer sufficient to meet mass production requirements.
In response, our company has developed a fully automated VCU assembly line for the client, covering the entire process from loading, dispensing, fastening, inspection, testing, labeling, final inspection, to packing and off‑line – all fully automated. This line effectively addresses the efficiency bottlenecks and quality risks inherent in manual production. The entire line features independent data management and storage capabilities, with full‑process traceability integrated with the MES system. It is also interconnected with intelligent logistics for AGV (Automated Guided Vehicle) docking, providing a reliable foundation for the client's large‑scale production of NEV electronic control components.
First、 Introduction to Core Equipment
Automated Loading/Unloading：Automatically sorts, conveys, and positions components – including upper housings, lower housings, and PCBA boards – with support for both AGV and manual loading modes to align with smart factory logistics systems. This improves feeding efficiency and ensures stable material supply for automated assembly.
Precision Fastening：Utilises torque + angle closed‑loop control screw fastening machines to automatically complete screw feeding and fastening, with data uploaded to the MES system in real time. This ensures precise, secure, consistent, and traceable fastening torque, eliminating quality risks such as under‑torquing and thread stripping.
Sealing Dispensing：Performs precision dispensing at critical locations – including upper/lower housings and PCBA – with CCD vision inspection for full verification of glue‑path position and volume, ensuring IP protection level compliance and sealing reliability.
Identification & Marking：Equipped with automatic labeling, laser marking, and vision inspection stations to automatically generate, apply, and verify product labels and markings, ensuring clarity, precision, and traceability. An innovative mechanism addresses the challenge of semi‑peeling backing paper.
Testing Process：Comprehensive testing stations – including leak testing, impedance and functional testing, PCB software programming, and final inspection – feature a redundant multi‑fixture design. The system automatically performs waterproof leak testing, electrical performance verification, and program programming, with defective products automatically diverted and data uploaded in real time.
Finished Product Handling：Automates rubber plug assembly, CCD quality inspection, and AGV‑docking for packing, completing the final automated finishing and warehouse transfer of finished products, ensuring delivery efficiency and product quality.
Smart Factory Digital Production Line：Seamlessly integrates with AGV‑based intelligent logistics, MES system data upload, and full‑process RFID traceability, supporting the client's transition toward an unmanned factory.
High‑Reliability E‑Control Component Manufacturing：Addressing the stringent safety and protection level requirements of new energy vehicles, the system provides fully automated solutions for IP67 waterproofing and full electrical performance inspection, ensuring product consistency and reliability.
Applicable Clients：
Established Market Leaders:For high‑volume production demands, the line delivers stable, rapid, and high‑quality manufacturing, easily handling peak‑season order delivery pressure.。
Emerging EV Manufacturers：Provides flexible automated production line solutions for rapidly iterating VCU products, supporting rapid changeover across multiple models and reducing the cost of mass production launch.
E‑Control Suppliers：Delivers standardised, replicable VCU assembly and test lines for professional automotive electronics suppliers, meeting the stringent quality and traceability requirements of diverse OEMs.
Consultation
