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Project Background
The AC/DC and DC/DC inverter assembly and test line is a flexible production system designed for core power conversion components in new energy vehicles, AI servers, and other applications. Integrating assembly and testing into a single system, it enables high‑volume production of AC/DC converters, DC/DC converters, and inverters, meeting automotive‑grade reliability and consistency requirements. The line supports mixed‑model production and complies with IATF 16949 standards.ACDC&DCDC逆变器装配测试线是适配新能源汽车、AI服务器等核心电力转换部件的柔性生产线，集装配、测试于一体，可实现ACDC转换器、DCDC转换器及逆变器的批量生产，满足车规级可靠性、一致性要求，适配多型号混线生产，符合IATF16949标准。
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 fully automatic/semi‑automatic assembly lines. 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 components – including housings, transformer inductors, EMI boards, etc. – 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：Performs vacuum potting of the OBC interior to enhance insulation, thermal conductivity, and vibration resistance.
Curing：Fully cures the potting and adhesive materials using specialised equipment, ensuring bonding and sealing integrity.
Inspection：Integrated throughout the entire process, inspecting both components and finished products to identify and reject non‑conforming items.
Leak Test：Conducts airtightness tests on the water cooling channels and the complete unit using precision instruments.
This assembly and test line is primarily focused on power conversion applications, with use cases spanning four major categories. It accommodates batch production, R&D trial runs, and after‑sales service requirements.
1、New Energy Vehicle Sector: Applicable to battery electric vehicles (BEVs), plug‑in hybrid electric vehicles (PHEVs) – both passenger and commercial – as well as special‑purpose new energy vehicles such as sanitation trucks and logistics vehicles. The line is used for the assembly and testing of AC/DC and DC/DC inverters, ensuring the stability and reliability of vehicle power conversion systems.
2、New Energy Vehicle Charging Infrastructure Sector:Used for the assembly and testing of AC/DC and DC/DC power conversion modules within charging stations, enabling efficient conversion between grid AC power and charging station DC power to support stable charging station operation.
3、AI Server Sector:Addressing the high‑power conversion requirements of AI servers, the line performs assembly and testing of internal AC/DC and DC/DC conversion modules, ensuring stable power delivery and efficient conversion under the high‑load, high‑reliability operating conditions typical of AI server environments.
4、Additional Applications:The line is also applicable to large‑scale production at electric drive system component suppliers, prototype testing for new vehicle model development, and re‑inspection and reassembly of returned products after‑sales. Furthermore, it can be extended to the production and testing of power conversion components in the energy storage sector.
Consultation
