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Auto Parts Assembly

Ride-Height Sensor Fully Automated Assembly & Calibration Line

Leading Domestic Chassis System Tier 1 Supplier2024

A fully automated assembly and calibration line for automotive ride-height (chassis position) sensors 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.

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建议尺寸 1600×900

Technical Specifications

Key parameters and delivery form.

Product type
Ride-height sensor (CPS)
Output interface
Analog / PSI5 / PWM
Takt time
≤ 5.5 s/piece
Injection
8-cavity mold
First-pass yield
FPY ≥ 99.5% (endurance run)
Availability
≥ 95%
Changeover
≤ 15 minutes
Capability
Cmk ≥ 1.67 · EOL Gage R&R < 10%

Scope of Delivery

  • Lead-frame auto feeding & IC resistance welding
  • Bridge cutting & laser activation
  • Multi-cavity injection overmolding & angus removal
  • DMC laser marking
  • Precision greasing & O-ring seal assembly
  • Shaft/lever servo press-fit & torque testing
  • Angle calibration, functional testing & automated palletizing

Process Highlights

  • 1Seventeen-process fully automated one-piece flow at ≤ 5.5 s/piece — automatic transfer from lead frame to finished-goods palletizing
  • 2100% grease weighing, O-ring vision poka-yoke, press-fit force-displacement curves and pull testing — full containment at high-risk stations
  • 3Per-piece angle calibration with an independent re-test loop after coefficient programming, securing Analog / PSI5 / PWM output accuracy
  • 4Chip ID and DMC linked across the process, per-piece parameters uploaded to MES, supporting customers' IATF 16949 audits
FAQ

Frequently Asked Questions About This Project

What did this ride-height sensor line delivery include?
The turnkey line delivered seventeen fully automated processes: lead-frame feeding, IC resistance welding, bridge cutting, laser activation, 8-cavity injection overmolding, angus removal, DMC marking, precision greasing, O-ring assembly, shaft/lever press-fitting with pull testing, homogenization and torque testing, angle calibration and functional testing, final customer marking and automated palletizing — validated in an endurance run at a leading domestic chassis system Tier 1 supplier.
What takt and yield levels does the line achieve?
Takt is ≤ 5.5 seconds per piece with ≥ 95% technical availability and first-pass yield ≥ 99.5% under the agreed uninterrupted endurance run. Key press-fit stations are designed for Cmk ≥ 1.67, EOL and calibration measurement systems are accepted at Gage R&R < 10%, and same-platform variant changeover takes ≤ 15 minutes.
How are the high-risk steps — greasing, seals and press-fitting — controlled?
All three use 100% inspection: grease is dosed quantitatively and each piece is weighed, O-rings are vision-checked for missing, twisted or damaged seals, and shaft/lever press-fitting records full force-displacement curves followed by pull testing; rotation torque is measured after a homogenization run. Any non-conforming piece is interlocked and isolated from the flow.
How is angular signal accuracy guaranteed?
Magnet batch tolerances, IC sensitivity spread and assembly coaxiality errors are eliminated by per-piece calibration: sampling at multiple known angles, computing correction coefficients and programming them into the IC, then re-testing at independent angle points to confirm Analog / PSI5 / PWM outputs fall within the specification window. Calibration data is linked to the chip ID and DMC and uploaded to MES for per-piece traceability.

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