Amid the three major waves of electrification, intelligence and lightweighting in the automotive industry, the importance of precision components has been pushed to an unprecedented height. Dongguan Zhongchuangxing Precision Machinery Manufacturing Co., LTD., as a key link in the automotive supply chain, is providing a solid manufacturing foundation for future mobility through technological innovation and process reform.
The transformation of the automotive industry and new requirements for components
Technological challenges under the trend of the new four modernizations
"Electrification
The voltage level has been raised from 12V to 800V
The current carrying capacity requirement is to be increased by 5 to 10 times
Electromagnetic compatibility has become a key indicator
"Intelligence
The number of sensors has increased from dozens to hundreds
The precision requirements for data interfaces have been raised
Reliability and durability are facing new tests
Connectivity
Demand for high-speed data transmission
Signal integrity requirements
Enhanced anti-interference ability
"Lightweighting
The materials are shifting from steel to aluminum, magnesium and composite materials
The structural design is more complex
The requirement for the strength-to-weight ratio is constantly increasing
Our technical response system
In response to these challenges, we have established four major technical platforms:
1. High-voltage connection system manufacturing platform
Technical architecture
Material research and development → Precision stamping → Surface treatment → performance testing
2. Intelligent sensor manufacturing platform
Process route
Precision forming → Micro-machining → cleaning treatment → functional testing
3. Lightweight structural component platform
Innovation path
Topological optimization design → multi-material connection → Precision control → fatigue verification
4. Reliability verification platform
Testing system
Environmental test → Mechanical test → electrical test → life prediction
Technical analysis of Core product lines
1. High-voltage connection system: The "blood vessels" of Electric vehicles
1. Product series
High-voltage connector (300V-1000V)
Battery module connection sheet
Motor terminal block
Charging interface component
2. Technological breakthrough
Material innovation
Developed high-conductivity copper alloy (conductivity > 95% IACS)
High-temperature resistant insulating materials (continuous working temperature 150℃)
Low contact resistance coating technology (contact resistance < 0.5mΩ)
3. Technological innovation
Manufacturing process of connecting plates
Precision stamping forming (accuracy ±0.03mm)
2. Silver brazing welding (temperature control ±3℃)
3. Ultrasonic cleaning (Cleanliness Class 100)
4. Laser marking traceability (permanent marking)
5. 100% electrical performance test (simultaneous detection of 5 parameters)
Quality control
Establish an independent quality file for each connection piece
Full-size three-coordinate measurement (100% inspection)
Metallographic structure analysis (sampling for each batch)
Temperature rise test (1.5 times rated current)
Actual achievements
It is applied to the battery pack of a certain new energy vehicle
The connection resistance is reduced by 15%
The temperature rise has decreased by 8℃
Passed the 2,000-hour durability test
2. Sensor housing: The "Sensing skin" of smart cars
Technical requirements
Material: Aluminum alloy 6061/ Stainless steel 316L
Dimensional accuracy: ±0.02mm
Sealing performance: IP67/IP69K
Electromagnetic shielding: > 60dB
Annual output: Over 1 million sets
Manufacturing Challenges and Solutions
Challenge One: Thin-walled sealing structure
The wall thickness is 0.8mm and it is necessary to ensure the sealing property
Traditional welding is prone to deformation
Our plan
Laser welding + roll forming composite process
The deformation is controlled to be less than 0.05mm
The pass rate of the sealing test is 99.9%
Challenge Two: Electromagnetic Compatibility
The sensor has high sensitivity but is prone to interference
High shielding performance is required
Our plan
Surface conductive oxidation treatment
Gap conductive adhesive filling
The measured shielding efficiency is greater than 70dB
Challenge Three: Batch Consistency
With a production volume of over a million, high quality stability is required
Our plan
Integration of automated production lines
SPC real-time monitoring system
100% visual inspection by machine vision
Production line configuration
Automated production line
Feeding robot → stamping unit → Welding unit →
Cleaning unit → Detection unit → Packaging unit
Cycle time: 12 seconds per piece, efficiency increased by 300%
