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%