New Delivery | HOLS Rolls Out Full OneBox Intelligent Production Line, Boosting Mass Production of Drive-by-Wire Chassis
View count:2026-06-26 View count:781
Industry Background: Soaring OneBox Demand Paired with Critical Mass Production Pain Points
With the rapid rollout of high-level autonomous driving and widespread adoption of centralized E/E architectures, integrated OneBox brake-by-wire systems have become the mainstream technical route, thanks to their lightweight design, high integration and superior energy recovery performance. Market installation volume maintains rapid growth year over year.
Nevertheless, as ultra-precise mechatronic-hydraulic safety components, OneBox manufacturing faces multiple tough bottlenecks: extremely strict assembly tolerance for valve blocks, near-zero error tolerance for ball rivet sealing, fragile flexible cups prone to assembly damage, complicated testing procedures for solenoid valves, slow model switching for mixed production, inconsistent batch quality, and insufficient full-process quality traceability. Many manufacturers hit roadblocks during capacity ramp-up, making stable mass production a core competitive threshold in the industry.
Drawing on years of process and delivery experience in drive-by-wire chassis automation, HOLS has delivered another complete OneBox assembly & testing line. Coupled with multiple previously delivered solenoid valve and core component production lines, we have built a full manufacturing chain from individual parts to complete assemblies. Leveraging self-developed precision processes and digital flexible production lines, we resolve widespread manufacturing pain points and form a closed-loop mass production workflow for brake-by-wire products.
1. Full-process Integrated Production Line Covering Complete OneBox Manufacturing Workflow
The newly delivered production line covers all core processes: solenoid valve feeding, precision pressing, steel ball riveting, cup sealing assembly, structural component integration and complete machine performance testing. It realizes integrated assembly and inspection of HCU, ECU and full OneBox assemblies, forming a closed loop of manufacturing and quality verification.
To address the industry’s needs of multi-model co-production and fast product iteration, the whole line is custom-designed around four major manufacturing challenges: multi-part compatibility, quick model changeover, stable process performance and full-lifecycle traceability. Drawing on HOLS’ proven experience from numerous similar projects, the line fundamentally mitigates manufacturing issues including complex OneBox structures, lengthy working procedures and unstable batch quality, laying a solid foundation for consistent mass production.
2. Self-developed Core Processes to Solve Precision Assembly Challenges
1. Steel Ball Riveting Process for Reliable Hydraulic Sealing
Industry Pain Points: Tiny deviations in valve block ball pressing easily lead to brake fluid leakage. Manual parameter monitoring cannot realize full real-time tracking; undetected issues such as missing steel balls or worn pressing heads create long-term safety risks.
HOLS Solution: The valve block boasts repeated positioning accuracy ≤0.05mm, paired with DC53 coated pressing heads (HRC58-62) for outstanding wear resistance. Force-displacement dual closed-loop monitoring records all process data in real time. Intelligent detection identifies missing/extra steel balls and damaged pressing heads, with automatic service life management and quick replacement support. All process data is bound and archived, enabling full traceability of every riveting operation and eliminating leakage risks at the source.
2. Cup Sealing Assembly with Visual Inspection to Eliminate Assembly Defects
Industry Pain Points: Flexible sealing cups are easily scratched or unevenly lubricated during manual assembly. Sealing failure drastically shortens the service life of brake assemblies, while conventional inspection fails to detect internal assembly flaws.
HOLS Solution: Automated precision atomized oil lubrication for cup grooves with real-time dosage monitoring for consistent coating. The entire assembly process is live-monitored via endoscope visual imaging. The system automatically verifies sealing ring placement to avoid scratches, offset or deformation, significantly improving sealing uniformity and durability of finished assemblies.
3. Automated Solenoid Valve Assembly with Full In-line Performance Verification
Industry Pain Points: Solenoid valves contain complex working steps with hard-to-control pressing parameters. Manual assembly delivers low efficiency and poor consistency; defective valves entering final assembly result in scrapped full OneBox units and severe production cost waste.
HOLS Solution: Fully unmanned automated assembly with cycle time ≤6 seconds per valve. Multi-axis servo precision pressing completes multi-stage calibration of stroke, air gap and electromagnetic force. High-precision pressure transmitters generate time-pressure curves to accurately determine the termination point of pressing via pressure drop gradient. 100% online recheck of coil current and cavity air pressure filters out defective valves in advance to guarantee stable hydraulic output of every finished assembly.
3. Mature Mass Production Capacity with Industry-leading Flexible Intelligent Manufacturing Indicators
Custom-built to resolve mass production pain points including insufficient throughput, low equipment availability, unstable yield and incomplete data traceability, the line delivers remarkable performance metrics:
- 1.Efficient Takt Time: OneBox assembly & testing line cycle time ＜45s; solenoid valve workshop equipment availability ≥85%, eliminating slow capacity ramp-up.
- 2.Stable Output Quality: Overall equipment OEE ＞85%, finished product yield ＞98%, drastically cutting losses from defective products and production costs.
- 3.High Flexible Mixed Production: Compatible with simultaneous manufacturing of multiple product variants; fast changeover adapts to frequent product iteration and multi-batch production schedules.
- 4.Full Digital Traceability: QR code binding for all working procedures; production, process and inspection data uploaded in real time, fully compliant with IATF16949 automotive quality standards to satisfy strict traceability audits from OEM clients.
- 5.Unmanned Full Operation: End-to-end automation from component feeding, assembly, inspection to finished product offline, minimizing human-induced errors and labor expenses.
With the complete set of mature process solutions validated by this OneBox project, HOLS provides differentiated customized flexible production lines matching each client’s unique factory layout, capacity targets and product iteration schedules, greatly shortening line commissioning cycles and accelerating the commercial mass launch of new products.
Company Profile
HOLS designs, customizes and delivers integrated intelligent production lines for precision assembly and full-process testing serving global diversified industries, functioning as a world-leading intelligent manufacturing solution provider specializing in high-end automotive chassis automation. Drawing on extensive chassis project experience, we have built a comprehensive brake-by-wire solution portfolio, delivering highly flexible, fully traceable complete production lines to resolve all types of precision component manufacturing challenges.
Headquartered in Suzhou, Jiangsu Province, HOLS integrates R&D, manufacturing, delivery and after-sales services. We operate two overseas service hubs, focusing on high-end automation sectors including automotive, semiconductors and new energy. Through technological innovation, proven delivery expertise and full-process quality control systems, we continuously support stable, high-quality mass production across all industries.