Electric Vehicle Charger Assembly Line
• 1. Diversified Technical Routes
Suitable for different types of charging stations: Slow charging stations (7kW - 22kW AC stations, simple structure, fast production cycle). Fast charging stations (60kW - 350kW DC stations, require integration of high-power liquid cooling modules). Ultra-fast charging stations (800V high-voltage platform, increasing demand for silicon carbide components)..
•2. Modular Design
Core components (such as charging modules, main control boards) adopt plug-and-play design, supporting rapid model change production. For example: The same production line can switch between producing household charging stations and commercial fast charging stations..
•3. High Degree of Intelligence
AI Quality Inspection: Machine vision detects oxidation defects of plug contact pieces. Digital Twin: Virtual debugging shortens the deployment time of the production line (such as the Siemens digital factory solution). MES System:
Real-time monitoring of production data (such as the pass rate of Tesla V3 ultra-fast charging station production line at 99.2%).
4. Strict Safety Standards
The production process must comply with international certifications (such as UL certification, CE certification, and China CQC certification). The high-pressure testing phase accounts for more than 30% of the total working hours..
Types and differences
|
Type |
Key process |
Difficulties in automation |
|
The AC charging station |
simple structure and high assembly efficiency. |
The wiring is standardized to avoid errors. |
|
Direct current charging station (DC) |
High-power module heat dissipation design |
Liquid cooling pipe sealing inspection |
|
Ultra-fast charging station (HPC) |
Multiple modules in parallel, high voltage testing |
Requires specialized high current testing equipment |
Case studies
• A certain automotive company's charging station factory:
◦ Automation rate of 80%, production capacity increased to 2,000 units per month.
◦ Test failure rate decreased from 3% to 0.5%.
Industry Trends
• Digital twin simulation optimizes production processes.
• AI predicts equipment maintenance failures.
• Recycles materials (such as recycled plastic casings).
• Tests power feedback technology to the grid.
• Plug-and-play charging modules for easy maintenance and upgrades.