HCU (Hydraulic Control Unit) is the core hydraulic control module of brake-by-wire systems including EHB, One-box and EMB, directly determining vehicle braking safety and pressure control precision. HOLS Automation’s turnkey HCU assembly & test line delivers full-process intelligent manufacturing, integrating precision assembly, multi-stage leak detection, electrical calibration and end-of-line performance testing. All critical processes adopt closed-loop servo control, fully meeting IATF 16949 automotive mass production standards.

Key Processes

1.Valve Body Precision Assembly

Complete steel ball press-fitting, master cylinder seal fitting, dual-chamber piston and firewall subassembly assembly. Servo force-displacement monitoring ensures zero internal leakage of the hydraulic base body.

2.Solenoid Valve & Sensor Press-Fitting

Automatic feeding, riveting and locking of SSV/PSV solenoid valves; micro press-fit of pressure sensors & PTS chips to guarantee stable pressure signal output.

3.Motor & PSU Subassembly Integration

Assemble power unit cylinder, anti-rotation structures and motor lead screw components, forming the core pressure adjustment power assembly.

4.Two-Tier Airtightness Inspection

Low-pressure tightness test after simulator assembly + high-pressure helium leak test post ECU mounting, detecting micro leakage at different hydraulic pressure levels.

5.Electrical Calibration & Functional Test

Complete PTS sensor and motor parameter calibration, followed by full-assembly comprehensive sealing test after oil pot installation.

6.ECU Programming & Finished Packaging

Flash customized customer brake control software, attach traceability labels and finish automatic packaging of qualified HCU units.