HCU (Hydraulic Control Unit) serves as the core hydraulic control actuator for all brake-by-wire architectures, covering EHB Electro-Hydraulic Brake, One-box integrated hydraulic braking system and EMB Electro-Mechanical Brake. It dominates vehicle braking stability, active safety performance and high-precision hydraulic pressure regulation, laying the foundation for ABS anti-lock braking, ESC electronic stability control and IPB integrated parking brake functions.
As a professional intelligent chassis non-standard automation solution provider, HOLS Automation delivers a complete turnkey HCU assembly & testing production line for mass manufacturing. The whole line realizes full-process intelligent closed-loop production, integrating precision mechanical assembly, electronic component press-fitting, electromagnetic force retesting and air gap adjustment procedures. Equipped with multi-station helium leak testing modules, it conducts strict air tightness inspection for brake valves, hydraulic pipelines and control unit housings to eliminate fluid leakage risks.
The production workflow also covers wiring harness assembly, electrical parameter calibration, hydraulic pressure matching and comprehensive EOL end-of-line performance testing. Every key workstation adopts high-precision closed-loop servo control, with full-lifecycle data traceability covering all assembly and test records. The whole production system strictly complies with IATF 16949 automotive-grade mass production specifications, and has mature delivery experience supporting global Tier 1 brake system manufacturers to produce EHB, EPB, ABS regulator and ESC hydraulic modules in batches.
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.
