Control Units

ASSEMBLY SOLUTIONS FOR SMART MOBILITY

Assembly lines and test systems for smart,
electronic control units

 

Control Units (ECU) combine a variety of safety and comfort functions and are used in a wide scope of mobility applications. Starting with engine and transmission control units, safety-relevant systems such as ABS and ESP, as well as the control of semi-autonomous driving operations, these units are used in most sensitive environments.

As foundation of the automotive electronics, the highest requirements in assembly and testing must be realized. In all key processes of automation, XENON offers extensively tested technology modules.

XENON competencies for control units:

  • Development know-how for core technologies
  • Micro-Strain-Test (Strain-Measurement)
  • ESD-compatible manufacturing plants
  • AOI of complex assemblies
  • Integration of EOL test systems in a temperature-controlled environment
  • Integration of external systems
  • Assumption of responsibility as general contractor
 

Key assembly processes

Eine Auswahl von Steuergeräten und -komponenten im Fahrzeug,
die von XENON Automaten montiert und getestet wurden.

Product Image
  • Steckverbinder Montage

    • Pressfit Montage
    • Löten
    • AOI Pinposition

  • Kühlkörper Montage

    • Plasma aktivieren
    • Wärmeleitpaste applizieren

  • PCB Montage

    • Kraft-Weg überwachtes Fügen
    • Einpressen
    • Verschrauben
    • Prüfen

    • Gehäuse Montage

      • Verschrauben
      • Crimpen
      • Dichtheitsprüfung
      • EOL Test

    • Identifikation

      • Labeln
      • Lasern
      • Markieren

    Zentrales Steuergerät - Assisted & Automated Driving Control Unit (ADCU)
    © Continental AG

     

    Key assembly processes

    Our wide expertise in technology is the perfect foundation for your individual automation solution.

    Product Image
    • Connector Assembly

      • Pressfit assembly
      • Soldering
      • AOI pin position

    • Heat Sink Mounting

      • Activating plasma
      • Apply thermal paste

    • PCB Assembly

      • force-displacement monitored joining
      • Press-fit
      • Screwing
      • Testing

    • Housing Assembly

      • Screwing
      • Crimping
      • Leak test
      • EOL test

    • Identification

      • Labelling
      • Lasering
      • Marking

    Customer products in operation

    A number of ECUs and components in a car,
    which have been assembled and tested by XENON automation systems.

    Product Image
    • Seat Control Units

      Enables the control of individually adjustable seat positions and comfort functions

    • Driver Assistance Systems

      Control units for assisted and automated driving

    • Steering Control

      The control unit calculates the required steering assistance of the electric power steering

    • Transmission Control

      Enables electronic control of the electrohydraulic or electromechanical transmission

    • ABS/ESP Control Units

      Control units for braking and driving dynamics

    • Antenna Module

      Intelligent interface between vehicle and the environment. Enables communication to other vehicles, mobile phones, GPS systems, …

    Ihre Vorteile – unsere Kompetenzen

    • Qualität & Sicherheit

      Die absolute Qualität Ihres Produktes und die maximale Sicherheit unserer Anlagen und Prozesse stehen an erster Stelle.

    • Komplexität & Präzision

      Die zentrale Herausforderung ist es, im Zuge von komplizierten Montagevorgängen die Bauteilqualität und -funktion zu gewährleisten.

    • Erfahrung & Innovation

      Langjährige Automatisierungserfahrung und umfangreiches Prozesswissen ermöglichen kurze Entwicklungszeiten und führen zu einer schnellen serienreifen Produktion

    High-Speed-Linear-Transportsystem

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    Modified Image

    System Capabilities

    • Maximum Flexibility

      • Flexible & Scalable Layout Options
      • Double/Bypassing of Processes
      • Use as singular WPC Transfer Changer

    • Effective Process Utilisation

      • WPC Change Time below 0,4s
      • Acceleration up to 4g
      • Maximum Speed up to 5m/s

    • High Process Stability

      • Accuracy up to +-0,01mm
      • use of WPC as additional process axis
      • Support for vertical process-forces

    • Suitable for Clean Room

      • Medical-Compliant for ISO-5
      • Stainless Steel covered Drives
      • No friction, No abrasion

    Modular Concept

    A mechatronic system containing all functions necessary for operation. A modular, fully integrated linear motor with power electronics and displacement measurement in one device. A mover as the moved part. A mechanical guide rail. The most diverse applications can be realised with these few coordinated components. The desired geometries, lengths and radii are formed by the number and choice of the components

    Linear Segment

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    Curved Segment

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    Vorteile gegenüber konventionellen Lösungen:

    • Flexible und individuelle Carrier Ansteuerung
    • Ermöglicht Optimierung von Taktzeiten
    • Parallelisierung von Prozessen möglich
    • Hohe Positioniergenauigkeit
    • Teil des Handlings Systems
    • Keine bewegten Kabel
    • Wartungsfreier Antrieb

    Rap Tra

    • Seit einem Jahr Grundsystem von Hoyer gekauft
    • Video Funktionsumfang für Website erstellen#
    • Individuelles Beratungsintesives System
    • Magnetischer Zahnriemen Motor
    • Kosten im Vergleich zum Wettbewerb

    Warum sollte sich der Kunde für RapTra entscheiden
    Auswahl Vergleichsdokument Auwahl Hoyer 

    • Vergleichswerte zum Wettbewerb (USP?)
    • X Achsen werden eingespart
    • Handlingeinsparung
    • Verssuchstand von Hoyer Folie nur in Blau bisher Umgesetzt
    • Puffer über Staustrecke möglich
    • Abriebfrei
    • Schnittstellen (Spec)

    Key Benefits

    •  Controlled movement at all times and all places on the transport path. No jerks and no unnecessarily large forces; high positioning accuracy at up to 4 m/s. Even open liquids can be transported
    • Dynamic buffer. The transported material can be accumulated and grouped during the movement.
    • Synchronisation, stopping and starting can be accomplished at any of the stations on the entire path
    • Maximum use of the machine volume. Outward and return path as well as the curves can actively transport material
    • The movers of the XTS system can always run with the flow of product. No return trip or return stroke is necessary. A change of format can be accomplished when changing product without stopping production, just by means of a software setting
    • Low mechanical wear since only the mover requires mechanical bearings. There is no need for: gears, belts, guide rollers and clamps
    • Reduced energy consumption due to lower friction and possible regenerative braking (the brake energy from one transported material can accelerate another)
    • High positioning accuracy reduces the expenditure. The compensation of inaccuracies as required in common transport solutions is not necessary: stretching of chains due to load and wear, re-tensioning of toothed belts, mechanical backlash during a load change

    Key technologies for control units

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    Pressfit-Assembly

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    (Vacuum-) dosing

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    Dosing Thermal Conductive

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    Screwing

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    Duroplast injection molding

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    Testing - Contact validation

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    Crimping

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    Welding

    30 Years of Automation Excellences

    REFERENCE PROJECTS

    Partially automated assembly of a transmission control unit


    Example References (TAL, ICM, ...) Evtl. Slider 

    To Do

    • Verlinkungen zu Referenzen Landingpage (TAL / ICM) (SGü, Ham)
    • Medical Veranstaltungen (Teaser Messen Medical) (SGü)
    • Videoclip TAL (SGü)
    • Bilder Kundenteile (SGü, Ham) 
    • Gesamtlayout und Texte überarbeiten
    • Medcell Informationen? (Pflichtenheft / Eigenschaften)
    • Sicherheit der Produkte und Fertigung
    • Auflistung Qualitätsstandards, QM & Sicherheit (GMP, ...)  
    • Fotos AP (SGü)
    • Innovationsthemen? (V2 - Augmented Reality)
    • Quotes von Kunden? (V2 - Ham) 

    Customer product

    Control unit for the adapted control of the automatic transmission

    Automation requirements

    • Assembly according to the chaku-chaku principle,
      input of components by operator
    • Realization of a one-piece-flow
    • ESD conformity throughout the assembly line
    • Feeding of materials
    • User-friendly in flow racks
    • Ergonomic manual workstations
    • Pressfit contacts
    • Traceability concept for linking the individual modules

    Assembly line for a steering control unit


    Example References (TAL, ICM, ...) Evtl. Slider 

    To Do

    • Verlinkungen zu Referenzen Landingpage (TAL / ICM) (SGü, Ham)
    • Medical Veranstaltungen (Teaser Messen Medical) (SGü)
    • Videoclip TAL (SGü)
    • Bilder Kundenteile (SGü, Ham) 
    • Gesamtlayout und Texte überarbeiten
    • Medcell Informationen? (Pflichtenheft / Eigenschaften)
    • Sicherheit der Produkte und Fertigung
    • Auflistung Qualitätsstandards, QM & Sicherheit (GMP, ...)  
    • Fotos AP (SGü)
    • Innovationsthemen? (V2 - Augmented Reality)
    • Quotes von Kunden? (V2 - Ham) 

    Customer product

    Control unit for steering control

    Automation requirements

    • Integration of 25 process modules (6 different suppliers)
    • Fully automated
    • Integration of the customer's MES after basic commissioning
    • Qualification and ramp-up
    • Integration of independent buffer stations for smoothing cycle time fluctuations

      Control unit for autonomous driving


      Example References (TAL, ICM, ...) Evtl. Slider 

      To Do

      • Verlinkungen zu Referenzen Landingpage (TAL / ICM) (SGü, Ham)
      • Medical Veranstaltungen (Teaser Messen Medical) (SGü)
      • Videoclip TAL (SGü)
      • Bilder Kundenteile (SGü, Ham) 
      • Gesamtlayout und Texte überarbeiten
      • Medcell Informationen? (Pflichtenheft / Eigenschaften)
      • Sicherheit der Produkte und Fertigung
      • Auflistung Qualitätsstandards, QM & Sicherheit (GMP, ...)  
      • Fotos AP (SGü)
      • Innovationsthemen? (V2 - Augmented Reality)
      • Quotes von Kunden? (V2 - Ham) 

      Customer product

      Control unit for autonomous driving

      Near Range Camera System
      Driver Assistance System

      Automation requirements

      • Semi-automated assembly line
      • Wide range of types (up to 20 different types)
      • Development of product series parallel to plant start-up
        (simultaneous engineering)

      Worldwide leading automotive companies rely on XENON automation systems

      Would you like to know more about our
      solutions for electronic control units?   
      Just give us a call.

      +49 351 40209-216

      Contact

      Your Contact

      Carsten Schumann
      Sales Manager

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