Chassis Position Sensor (CPS) Fully Automated Assembly & Calibration Line

Delivered in 2024 to a leading domestic chassis system Tier 1 supplier (shown as an industry-generic description under customer confidentiality constraints), the ride-height sensor line runs seventeen fully automated processes in one-piece flow, from lead-frame feeding to finished-goods palletizing. The sequence covers IC resistance welding, bridge cutting and laser activation, 8-cavity injection overmolding with angus removal, DMC marking, precision greasing and O-ring seal assembly, shaft and lever press-fitting, angle calibration and functional testing, with automatic transfer between every station.

The line is balanced to a takt of no more than 5.5 seconds per piece with technical availability of at least 95%, and first-pass yield of 99.5% or better was confirmed under the agreed uninterrupted endurance run. Key press-fit stations are engineered to a Cmk of at least 1.67, the EOL and calibration measurement systems are accepted with Gage R&R below 10%, and same-platform variants change over within 15 minutes — the combination of capability and measurement controls is what keeps a high-speed automated line shipping conforming sensors rather than sorting them afterward.

High-risk processes all use 100% containment: grease is dosed quantitatively and weighed per piece, O-rings pass a vision poka-yoke for missing, twisted or damaged seals, and shaft and lever press-fitting is recorded as full force-displacement curves followed by pull testing and torque measurement. Angular accuracy is secured by per-piece calibration — sampling at known angles, programming correction coefficients into the IC, then re-testing at independent points so the Analog, PSI and PWM outputs land inside the specification window. Each calibration record is linked to the chip ID and DMC, and the per-piece process parameters upload to MES for full traceability and IATF 16949 review.