ASSEMBLY SOLUTIONS FOR SMART MOBILITY
Assembly lines and test systems for
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
Our wide expertise in technology is the perfect foundation for your individual automation solution.
Customer products in operation
A number of ECUs and components in a car,
which have been assembled and tested by XENON automation systems.
Key technologies for control units
Pressfit-Assembly
(Vacuum-) dosing
Dosing Thermal Conductive
Screwing
Duroplast injection molding
Testing - Contact validation
Crimping
Welding
REFERENCE PROJECTS
Partially automated assembly of a transmission control unit
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
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
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)