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Project Background
The Power Distribution Unit (PDU) assembly line is an automated/semi‑automated flexible production line specifically designed for NEV power distribution units. It integrates parts feeding, assembly, fastening, dispensing, potting, curing, selective soldering, AOI inspection, testing, and packaging into a single system, meeting automotive‑grade high‑reliability and high‑consistency production requirements.
Multiple projects have been implemented at benchmark enterprises in the domestic automotive industry. In response to the rapid growth of new energy vehicle production capacity and the increasing demand for product consistency, the client plans to build a fully automatic/semi‑automatic PDU assembly line. The system, through automated fixture circulation, is expected to optimise efficiency, stabilise quality, reduce energy consumption, and enable data‑driven traceability management.
The current manufacturing processes are primarily confronted with the following challenges:
✅ Low manual assembly efficiency and poor quality control, making it difficult to meet capacity expansion needs.
✅ Lack of standardised operating procedures, resulting in insufficient product consistency.
✅ Absence of real‑time monitoring and data traceability mechanisms.
To address these issues, the client has decided to introduce an automated/semi‑automated assembly line solution to enhance production efficiency and product reliability.
First、Introduction to Core Equipment
Automated Loading/Unloading：Automatically sorts, conveys, and positions various PDU components, improving feeding efficiency and enabling automated assembly.
Fastening：Utilises servo‑driven screw fastening machines with integrated sensors to automatically complete screw feeding and fastening, with data uploaded to the AMES system, ensuring secure, consistent, and traceable fastening.
Assembly：Precisely assembles components using dedicated equipment, ensuring proper fit and alignment.
Dispensing：Precisely applies sealing compounds, thermal interface materials, and RTV silicone to guarantee product sealing and thermal conductivity.
Potting：Fills the interior of the PDU with potting compound to enhance insulation, thermal conductivity, and vibration resistance.
Curing：Fully cures the potting and adhesive materials using specialised equipment, ensuring bonding and sealing integrity.
Selective Soldering：Uses specialised equipment to securely solder pins, ensuring product robustness and stable performance.
Inspection：Integrated throughout the entire process, inspecting both components and finished products to identify and reject non‑conforming items.
This production line equipment is applicable to power distribution unit manufacturing enterprises.
Applicable Manufacturers Include:
1. New Energy Passenger Vehicle SectorCommercial and Special‑Purpose Vehicle Secto：Suitable for high‑volume production of mainstream PDUs for battery electric sedans and SUVs, meeting the miniaturisation and high‑precision assembly requirements of passenger vehicle PDUs.
2. Commercial and Special‑Purpose Vehicle Sector：Used for assembly of high‑power PDUs for electric buses, logistics vehicles, and sanitation trucks, addressing the fastening, potting, and inspection demands of high‑power PDUs to ensure high product reliability.
3. New Energy Component Manufacturers：Supplied to e‑drive system suppliers and automotive electronics factories, enabling standardised, large‑scale PDU production with improved manufacturing efficiency and product quality.
4. New Model Trial Production and Small‑Batch Validation：Through flexible equipment configurations, the line supports prototype assembly during the R&D phase and small‑batch validation, accommodating rapid changeover across multiple models.
5. After‑Sales Service and Remanufacturing：Compact inspection, dispensing, potting, and curing equipment configurations are available for PDU repair, performance re‑validation, and re‑potting, restoring product performance after service returns.
Consultation
