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Project Background
Multiple projects have been implemented at benchmark enterprises in the domestic automotive industry. In response to the sustained surge in new energy vehicle sales, the Motor Control Unit (MCU) – as a core power control component – is experiencing explosive demand growth, placing rigid requirements on production capacity and delivery efficiency. Furthermore, MCUs are evolving toward higher power density, higher integration, and higher reliability, involving high‑voltage safety, precision assembly (e.g., IGBT modules, water‑cooling plates), and multi‑dimensional EOL testing (electrical, insulation, burn‑in, leak testing). Manual operations are no longer capable of meeting the required precision and consistency.
The current manufacturing processes are primarily confronted with the following challenges:
✅ Low assembly efficiency：Processes such as screw fastening, adhesive dispensing, press‑fitting, and harness connection rely heavily on manual labour, resulting in slow cycle times (significant assembly time per unit), limited production capacity, and heavy pressure on order delivery during peak seasons.
✅ Low testing efficiency：Manual cable insertion/removal, parameter setting, and data recording prolong test cycles, leading to frequent omissions or misjudgments and high rework rates.
✅ Poor workflow continuity：Manual material handling introduces excessive waiting times, low line balance, and overall capacity bottlenecks.
✅ Lack of assembly precision：Manual screw fastening leads to inconsistent torque, component misalignment, and uneven sealant application, causing risks such as poor contact, water leakage, and abnormal noise.
✅ Poor test reliability：Non‑standardised manual testing procedures and non‑real‑time data recording increase the risk of defect escapes, leading to field failures and brand damage.
✅ Difficult process traceability：Manual data recording is fragmented, making it difficult to pinpoint root causes (e.g., equipment, materials, personnel) of defects, thereby hindering closed‑loop quality management.
To address these issues, the client has decided to introduce an automated assembly and test solution to enhance production efficiency and product reliability.
Equipment Overview and Core Capabilities
1.This automated motor control unit assembly and test line is a fully intelligent whole‑line system purpose‑built for NEV main drive motor controllers and three‑in‑one / multi‑in‑one e‑drive assemblies. It integrates automated loading, precision assembly, process treatment, comprehensive performance testing, defective sorting, data traceability, and material flow management. The line supports mixed‑model production for SiC‑based e‑control units, IGBT‑based conventional controllers, and a wide range of high‑ and low‑power MCU variants.
2.The entire line employs a double‑speed chain / roller conveyor layout with standardised pallet carriers, featuring robotic handling, servo presses, vision inspection, precision fastening, leak testing, and high‑voltage EOL (End‑of‑Line) testers as core units. These are integrated with a PLC central control system, an MES data interface module, and an RFID product tracking system to achieve fully automated operations from component entry to finished product off‑line.
3.The overall automation rate of the line reaches 80%–90%, with only a minimal number of manual workstations retained for auxiliary loading/unloading. It enables unmanned material flow across all process steps, with a stable mass‑production takt time. The line is adaptable to various annual production capacities ranging from 50,000 to 300,000 units, and supports single‑shift, double‑shift, and triple‑shift continuous operation. It significantly reduces labour dependence and addresses the pain points of recruitment difficulties and low manual efficiency.
4.Leveraging technologies such as 3D vision positioning, servo press force‑displacement monitoring, closed‑loop torque fastening, and glue‑path vision inspection, the line strictly controls IGBT press‑fit clearance, screw fastening torque, sealant application trajectory and thickness, and component alignment accuracy. Assembly defects – including improper fitting, missing parts, uneven torque, sealing failure, and poor contact – are eliminated at the source. The first‑pass yield rate of finished products consistently exceeds 99.8%.
5.The line integrates all mandatory tests for the full lifecycle of motor control units, including insulation withstand voltage, high‑voltage safety compliance, air‑tight leak testing, low‑voltage wake‑up, CAN communication, voltage/current calibration, load performance, thermal simulation, endurance burn‑in, and fault diagnostics. The testing process is standardised and fully automated with one‑button operation, automatically classifying results as OK/NG, eliminating manual omissions and misjudgments, and meeting stringent OEM incoming inspection standards.
This equipment is applicable to high‑volume production of electric drive and e‑control systems for new energy vehicles, while also covering commercial vehicles, construction machinery, rail transit, energy storage, and industrial drive applications. It supports the full spectrum of production needs – from single e‑control units to multi‑in‑one e‑drive assemblies, and from small‑batch trial runs to high‑volume mass production.
Applicable Manufacturers Include：
OEM In‑House E‑Drive Plants and E‑Control Workshops
NEV Component Manufacturers, E‑Drive System Suppliers, and Specialised E‑Control Manufacturers
Manufacturers and Supporting Factories for New Energy Buses, Heavy‑Duty Trucks, Light‑Duty Trucks, Logistics Vehicles, Sanitation Vehicles, and Port Tugboats
Manufacturers of Excavators, Loaders, Bulldozers, Forklifts, Aerial Work Platforms, and Electric Agricultural Machinery
OEM R&D Centres, Start‑Up E‑Drive Companies, University Research Institutes, and Customised E‑Control Solution Providers
Consultation
