Delivered Projects
Case Studies
Thermal‑management flow‑channel cleaning for liquid cooling · Auto Parts Assembly — Delivery Portfolio
Below are representative projects we've delivered — across thermal cleaning and automotive parts assembly. Client names are anonymized per confidentiality agreements.
0production linesDelivered projects
0core domainsBusiness focus
Tier 1leading domestic clientsCustomer tier
What are ESML's precision cleaning, assembly, testing and automation case studies?
The case-study collection is a portfolio of real custom equipment ESML has delivered, covering thermal flow-channel cleaning and automotive-parts intelligent assembly. Each entry follows the operating flow of step 1 requirements review, step 2 design, step 3 build & integration, step 4 verification and step 5 on-site deployment, and lists measured results vs. the pre-project baseline. Customers appear as industry-generic descriptions under confidentiality constraints, while the processes, parameters and delivery scope are real.
Core productTIER 01 / 03
Thermal‑management flow‑channel cleaning for liquid cooling
2026Leading Domestic Thermal Management Tier 1
Integrated Thermal Flow-Channel Cleaning Line
- Challenge
- Delivered an integrated flow-channel cleaning system covering cleaning, drying, and cooling — meeting the cleanliness and cycle-time requirements of new-energy thermal management products.
- Solution
- Aqueous precision cleaning chamber
- Multi-stage high-efficiency drying
- Air / nitrogen cooling
- Results
- Clean → Dry → Cool (integrated)Process
- Micron-level removalParticle control
- Cold plates / Manifolds / HX / Liquid lines / Oil coolersWorkpieces
View case detail
2026Leading Domestic Thermal Management Component Manufacturer
Hydrogen-Nitrogen Leak Testing Equipment
- Challenge
- Solution
- Hydrogen-nitrogen leak testing system
- Results
- Hermetic leak testingProduct type
- Semi-automatic (fully automatic optional)Automation
- LeakageTest item
View case detail
TIER 02 / 03
Auto Parts Assembly
2025Leading Automotive Sensor Tier 1
Eddy-Current Sensor Fully Automated Assembly Line
- Challenge
- ESML's automotive sensor automation equipment — a fully automated assembly and inline inspection line for automotive-grade eddy-current sensors, covering flexible multi-part feeding, precision press-fitting, vision/force-position/functional inspection, functional and EOL testing, and automated sorting. A modular design enables quick multi-variant changeover; key-station data is traceable and MES-integrable. Designed and built to automotive-grade quality requirements, supporting customers' IATF 16949 audit requirements — serving a leading domestic automotive sensor maker.
- Solution
- Flexible multi-part feeding
- Precision press-fitting
- Vision & position inspection
- Results
- Eddy-current sensorProduct type
- Flexible feeding + press-fit + test/sortAutomation
- Vision / Force-pos / FunctionalInspection
View case detail
2026Top Automotive Ignition Coil Maker in China
Ignition Coil Bobbin Automated Assembly Line
- Challenge
- Multi-process automated assembly equipment for ignition coil bobbins — combining feeding, assembly, and inspection to meet the customer's cycle-time and stability requirements.
- Solution
- Automated multi-part feeding
- Multi-station auto assembly
- Inline inspection
- Results
- Ignition coil bobbinProduct type
- Auto feed + multi-station assemblyAutomation
- Assembly + weld/crimp + testProcess
View case detail
2025Automotive Electronics EMS
Injection-Molded Shell Auto Test & Sorting Equipment
- Challenge
- Automated test equipment for dielectric-withstand and airtightness of automotive electronic injection-molded shells, with auto loading/unloading and defect sorting — replacing manual offline inspection.
- Solution
- Auto load/unload
- Dielectric withstand test
- Airtightness test
- Results
- Auto electronic injection shellProduct type
- Withstand voltage + airtightnessTests
- Auto load/unload + sortAutomation
View case detail
2026Smart-Cabin Actuator Supplier
SMA Wire Actuator Intelligent Assembly Equipment
- Challenge
- Precision positioning, assembly, and functional testing equipment for shape-memory alloy (SMA) wire actuators used in seat massage modules.
- Solution
- SMA wire precision positioning
- Assembly & fixing
- Powered functional test
- Results
- SMA wire actuator assemblyProduct type
- Precision positioning + assembly + testKey process
- Auto assembly + inline inspectionAutomation
View case detail
2025Automotive Brake System Supplier
Brake Pad Shim Automatic Bending & Forming Equipment
- Challenge
- Automatic bending and forming equipment for multi-layer composite brake pad shims — integrating servo bending, inline angle inspection, springback compensation, and defect sorting to meet automotive-grade consistency.
- Solution
- Servo bending & forming
- Inline angle inspection
- Automatic springback compensation
- Results
- Brake pad shimProduct type
- ±0.5°Angle precision
- Servo bend + closed-loop angleKey process
View case detail
2025Leading Domestic Chassis System Tier 1 Supplier
Chassis Position Sensor (CPS) Fully Automated Assembly & Calibration Line
- Challenge
- A fully automated assembly and calibration line for automotive Chassis Position Sensor (CPS) delivered to a leading domestic chassis system Tier 1 supplier — covering lead-frame feeding, IC resistance welding, injection overmolding, DMC marking, precision greasing and seal assembly, shaft/lever press-fitting, angle calibration and functional testing, and automated palletizing. Takt ≤ 5.5 s per piece, first-pass yield ≥ 99.5%, with 100% inspection at high-risk stations. Chip ID and DMC are linked across the full process and MES-integrable, supporting customers' IATF 16949 audit requirements.
- Solution
- Lead-frame auto feeding & IC resistance welding
- Bridge cutting & laser activation
- Multi-cavity injection overmolding & angus removal
- Results
- Chassis Position Sensor (CPS)Product type
- Analog / PSI5 / PWMOutput interface
- ≤ 5.5 s/pieceTakt time
View case detail
2025Leading Accelerator Pedal Manufacturer
Automotive Accelerator Pedal Assembly Line
- Challenge
- Solution
- Automated pedal assembly line
- PCBA automatic welding equipment
- Accelerator pedal calibration & performance testing equipment
- Results
- All types of automotive accelerator pedalsProduct type
- Linearity / synchronization / clamp measurement / pulse width / pedal force / hysteresis / othersPerformance tests
- Servo press-fitting, robotic welding, CCD inspection, chip programming, FCT testingCore processes
View case detail
PROCESS
Delivery Process
From discovery to delivery to support — a five-stage closed loop for custom automation.
- 01
Discovery
- Site survey
- Process analysis
- Requirements sign-off
- 02
Design
- CAD modeling
- Component selection
- Design review
- 03
Prototype
- Pilot build
- Performance test
- Joint review
- 04
Delivery
- Assembly & tuning
- Line commissioning
- UAT sign-off
- 05
Support
- Spare parts
- Remote support
- Iterative upgrade
FAQ
Frequently asked questions about the case studies
Why are customers shown with generic descriptions?
Under customer confidentiality constraints, delivered projects use industry-generic descriptions (such as “leading domestic thermal management Tier 1 supplier”), while the equipment processes, parameters and delivery scope are real. More detail can be provided under NDA during discussions.
Can we visit a reference line?
Delivered lines are located on customer sites, and visits require customer consent. You are welcome to visit ESML in Suzhou High-tech Zone to discuss solutions first; we can also provide videos and materials for similar equipment.
Can a similar line be replicated from a case?
Yes. The cases use modular designs and can be quickly replicated and adjusted per product drawings, takt and cleanliness targets. The thermal flow-channel cleaning line is delivered, validated and ready for fast deployment.
Why are there no AI board-test cases?
The AI board-test business is under customer confidentiality constraints; the site describes capabilities and the design process only, with no projects or customers listed.
Updated · reviewed monthly
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