1.Project background

AVIC Optoelectronics is a mainstream new energy vehicle company in China. With the intensive launch of new models, there is an urgent need for self-research and production of battery thermal management modules. The original outsourcing supply model has problems such as long delivery cycle, difficult quality control, and high cost. It is urgent to build an automated production line that meets vehicle regulations to achieve independent control of core components.

2. Core pain points

1. Vehicle-level quality standards are strict, and battery thermal management and sealing performance are directly related to battery safety, requiring extremely high assembly accuracy and detection reliability;

2. The model iteration is fast, and it needs to support the co-production of thermal management modules for multiple models, which requires high flexibility of the production line;

3. The automotive supply chain has strict traceability requirements, and full-link data traceability from parts to finished products needs to be achieved to meet the requirements of the IATF16949 system;

4. The self-built production line has a tight cycle and high requirements, and needs to be implemented quickly and pass the vehicle quality system audit.

3. Overall solution

Guangke Industrial strictly follows the OEM-level quality standards to build a fully automatic assembly and test line for battery thermal management modules for customers. The production line adopts a modular and flexible design, integrating precision assembly, multi-station airtightness testing, water flow performance testing and a full-process traceability system to fully meet vehicle regulations and control requirements. It also supports co-line production of multiple vehicle models to ensure rapid production launch and long-term adaptability.

4. Solution core configuration

1. Automotive grade production line design: The entire process follows the IATF16949 quality system requirements, key features are 100% controlled, and meets CC/SC special feature control standards;

2. High-precision sealing assembly: robot precision assembly + intelligent fixed-torque tightening, the assembly force of key interfaces is accurately controllable, ensuring the reliability of sealing connections;

3. Multi-dimensional testing system: Integrate multi-station air tightness testing, water flow performance testing, and visual appearance testing to comprehensively verify core performance such as product sealing, flow rate, and pressure drop;

4. Full-link traceability system: From parts batches to finished products, RFID binds the entire process data, and assembly and testing information is completely retained to meet the traceability requirements of the automotive supply chain;

5. Flexible compatibility with multiple models: Modular tooling design supports co-line production of thermal management modules for multiple models, allowing rapid model change to adapt to the launch of new models;

6. Production visual management: equipped with production dashboard and data management system, real-time monitoring of production status, and automatic statistical analysis of quality data.

5. Project implementation results

1. Rapid mass production: the production line was delivered and put into production on schedule, and successfully passed the OEM quality system audit, supporting the timely mass production and launch of new models;

2. Excellent quality performance: the factory yield of finished products is stable at 99.6%, the sealing performance has zero batch failures, and the operation is stable and reliable after loading;

3. The traceability system meets the standards: the whole link data is completely traceable and fully meets the IATF16949 system and vehicle supply chain audit requirements;

4. Flexible adaptation to model iterations: Mass production adaptation of thermal management modules for 3 models has been completed, with a short model change cycle, which strongly supports the pace of model iterations.

6. Customer value and evaluation

The implementation of this production line has helped AVIC Optoelectronics achieve independent control of the core components of battery thermal management, significantly reducing outsourcing procurement costs and supply chain risks. At the same time, stable quality and a complete traceability system have also become an important support for customers' vehicle quality control, and have been highly praised by customers.