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Project Background
IGBT is a core component of the electronic control system in new energy vehicles, serving as the "power CPU" of the e‑control system. It is responsible for power conversion and motor drive, directly impacting driving range, charging speed, and overall vehicle reliability.
The IGBT power module assembly line is an automated/semi‑automated flexible production line specifically designed for NEV power modules. It integrates parts feeding, assembly, fastening, dispensing, soldering, inspection, and unloading 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 IGBT power module 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
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 structural adhesives to secure electrical components, preventing solder joint detachment and corrosion.
Inspection：Performs comprehensive inspection of IGBT pins, solder joint quality (bridging, insufficient solder, missing solder), screw fastening integrity (missing screws), and surrounding components (damage, missing parts, solder balls) – identifying and rejecting non‑conforming items.
Testing：Includes ICT (In‑Circuit Testing) for solder joint quality verification, component assembly validation, and parameter measurement; and FCT (Functional Circuit Testing) for functional logic verification, real‑world environment simulation, and comprehensive defect detection.
Automated Unloading：Automatically unloads IGBT modules onto material carts, facilitating convenient transport and positioning.
This production line equipment is applicable to IGBT module manufacturing enterprises.
Applicable Manufacturers Include:
1. Vehicle E‑Control Assembly Lines：For OEMs and Tier 1 component suppliers' e‑control workshops, supporting high‑volume, standardised production of IGBT modules that directly integrate with in‑house or integrated e‑control assemblies, enabling coordinated and integrated production across the line.
2. Tier 1 Component Suppliers：For leading enterprises in electronic control systems and e‑drive axles (including three‑in‑one and multi‑in‑one e‑drive systems), enabling self‑built IGBT assembly lines to achieve in‑house R&D and production of core components, thereby reducing costs and securing supply.
3.Standardised Smart Manufacturing Parks in Industrial Zones：For NEV component industrial parks and power semiconductor industrial parks, supporting centralised, high‑volume manufacturing with clustered production models that align with scalable, ecosystem‑based supply chain requirements.
4.Small‑Batch Custom R&D Lines:：For R&D pilot lines in automotive OEMs, research institutes, and semiconductor companies, supporting sample prototyping, small‑batch validation, and process iteration for new IGBT modules and integrated power modules.
5. After‑Sales Repair and Spare Parts Production:：For dedicated assembly/refurbishment lines in leading auto parts companies, supporting remanufacturing, refurbishment, and inspection of IGBT modules for after‑market replacement applications, addressing the maintenance and service demands of the repair market.
Consultation
