1.Project background

Yingxue Technology is a domestic supplier of body electronic systems, and its core product body controller (BCM) is supporting many mainstream car companies. As iterations of new energy vehicles accelerate and controller types increase rapidly, the original semi-manual production line has low testing efficiency and poor consistency, making it difficult to meet vehicle-level quality control and multi-variety flexible production needs. There is an urgent need to upgrade fully automatic assembly and testing production lines.

2. Core pain points

1. There are many product models and small batches, manual model change is cumbersome, and the production line is not flexible enough to adapt to rapid iterations of multiple models;

2. The functional test items are complex, manual operation + naked eye judgment is inefficient, and the misjudgment rate is high, making it difficult to ensure factory consistency;

3. The core assembly process relies on manual labor, the accuracy fluctuates greatly, product reliability is unstable, and the after-sales repair rate is high;

4. Production and testing data are scattered and the quality traceability chain is incomplete, making it unable to meet the OEM's IATF16949 audit requirements.

3. Overall solution

In response to Yingxue Technology's core needs of multiple varieties, high quality, and high traceability, Guangke Industrial has customized a complete line solution for flexible assembly and testing of body controllers. It adopts modular work station design, integrates precision assembly, fully automatic functional testing, aging verification and full-process traceability systems to realize full-process automation from PCB loading to final testing of finished products, taking into account production efficiency and flexible adaptability, and comprehensively benchmarking vehicle-level quality standards.

4. Solution core configuration

1. Flexible automated assembly unit

The core workstation uses robots + visual positioning operations to complete processes such as PCB plug-ins, case pressing, and intelligent screw tightening. The assembly parameters are fully controllable; the modular tooling design supports rapid changeover of multiple types of controllers.

2. Fully automatic functional test system

Integrated online ICT/FCT test, automatically completes continuity detection, voltage and current calibration, functional logic verification, CAN/LIN communication test, the test program automatically matches the model, and the results are automatically determined, eliminating manual errors.

3. High and low temperature aging verification unit

Finished products are subjected to high and low temperature aging tests under simulated working conditions to detect early failure risks in advance, improve product environmental adaptability and long-term reliability, and reduce after-sales failure rates.

4. Whole-process quality traceability system

A unique traceability code is bound to a single product, and assembly parameters, test data, and aging results are automatically recorded throughout the entire process. It supports two-way traceability between batches and single pieces, and meets the audit requirements of the vehicle supply chain.

5. Production visual management

The supporting electronic signage in the workshop displays the output, yield, and test abnormality distribution in real time, making the production status transparent and facilitating rapid on-site optimization.

5. Project implementation results

1. Production efficiency increased by 35%: the core process is fully automated, the entire line rhythm is greatly improved, the single-shift production capacity increases by 35%, and the labor investment is reduced by 40%;

2. The test accuracy rate has been greatly upgraded: fully automatic test judgment, the test misjudgment rate has dropped to less than 0.1%, and the factory yield has stabilized at more than 99.5%;

3. Enhanced flexible model change capabilities: Product model change time is shortened by 70%, supporting the co-production of more than ten controllers, perfectly adapting to the iteration rhythm of multiple models;

4. Quality traceability is fully up to standard: the whole link data is completely traceable, it has successfully passed the quality system audits of multiple OEMs, and the supply chain qualifications have been upgraded.

6. Customer value and evaluation

After this production line was put into production, it completely solved the efficiency and quality pain points of Yingxue Technology's multi-variety production of body controllers, and supported the rapid mass production of multiple new model projects. Stable product consistency and a complete traceability system help customers successfully enter the supply chains of more high-end car companies, significantly improving market competitiveness.