E-Pedal acts as the core human-machine control component of brake-by-wire systems for intelligent and new energy vehicles, delivering integrated acceleration and braking signal collection.
HOLS Automation’s custom non-standard turnkey production line integrates precision electronic component press-fitting, sensor installation, signal calibration, helium leak inspection and full EOL performance testing. Supported by full-process data traceability and closed-loop servo control, the line fully meets IATF 16949 automotive standards, supporting mass production of E-Pedal assemblies for global chassis Tier 1 manufacturers.
Production Process
The assembly line follows a streamlined, error-proof workflow to eliminate manual errors and ensure quality at every step:
1.Parts Feeding & Positioning
All core components, including pedal arms, return springs, sensors, and mounting brackets, are automatically fed and precisely positioned into dedicated fixtures. This eliminates misalignment and prepares parts for the next assembly stage.
2.Servo Press-Fit & Component Assembly
Servo-controlled press stations perform precise press-fit of critical parts such as pivot pins and sensor housings. Force-displacement monitoring ensures each assembly meets specified tolerances and avoids component damage.
3.Sensor Calibration & In-Line Testing
Integrated test stations calibrate the pedal position sensor, verifying output linearity, signal accuracy, and response consistency. Real-time data checks flag deviations before moving to final validation.
4.Functional & Durability Testing
End-of-line testing validates full pedal function, including travel, actuation force, return speed, and electrical signal integrity. Optional fatigue cycle simulation ensures long-term performance under repeated use.
5.Marking, Traceability & Sorting
Each finished pedal receives a unique laser mark for full traceability, linking it to production data and test records. The line automatically sorts qualified and non-conforming units, ensuring only defect-free products move to packaging.
