A leading electronics manufacturer in the USA partnered with JOT Automation to automate their BEV ECU assembly and testing line. The result: a compact, fully integrated microfactory solution that handles 14 complex applications in a minimal footprint.
The challenge – automate complex ECU assembly in limited space
Our customer needed to automate the complete assembly and testing process for their Battery Electric Vehicle Electronic Control Unit (BEV ECU) product. The manufacturing process included multiple intricate steps requiring high precision, from component feeding and assembly to ROM writing, laser marking, and comprehensive electrical testing.
The key challenges were:
- Complex multi-component assembly requiring precise placement and verification of clips, cases, covers, and PWBs
- Limited factory floor space demanding a compact automation solution
- High-mix production with multiple product types requiring different clip configurations and PWB combinations
- Stringent Tier 1 quality requirements including vision inspection, electrical testing, and traceability
- Integration with customer systems for MES communication and ROM writing
Manual production of these ECUs was proving inefficient, with poor ergonomics from repetitive assembly tasks, complex assembly and testing application requirements, and the challenge to maintain consistent quality at the required production volumes. The customer needed a fully automated solution that could handle the entire process while maintaining flexibility for product variations.
The solution – ANT Plant modular microfactory
JOT Automation delivered a complete turnkey solution based on our ANT Plant microfactory platform. The system integrates advanced robotics, machine vision, and flexible component feeding into a compact, modular cell design.
Core system components:
- 2 ABB IRB1300 robots handling multiple assembly and inspection operations
- Beckhoff PC/PLC control system
- Keyence MDX2520A laser marking system
- Advanced vision systems for quality verification
- 2 flex feeders for bulk case and cover feeding
- 2 bowl feeders for clip feeding
- JOT tray feeder for PWB handling
- Custom ROM writing fixture integrated with customer's system
- Multiple custom functional electrical test heads
The complete manufacturing process:
The ANT Plant cell manages the entire production flow from component feeding through final inspection:
- Component feeding – Black and white clips fed via bowl feeders with color verification, cases and covers presented via flex feeders, and PWBs loaded from trays with barcode reading
- Clip assembly – Robots assemble the correct clip combination to cases based on product type, with vision verification of clip seating and positioning
- ROM writing – PWBs undergo automated software flashing in a custom nest with probe pin engagement, taking approximately 6-7 seconds per unit
- PCB assembly – Successfully flashed PWBs are placed into cases with stroke sensor verification
- Laser marking – Covers are laser marked with 2D codes and verified by integrated reader
- Data association – PWB and cover barcodes are linked in the MES system for complete traceability
- Cover assembly – Robots place laser-marked covers onto assembled cases
- Vision inspection – Hook and claw fitting verified by vision system, with partial sets flagged for operator attention
- Electrical testing – Multiple parallel test fixtures enable 90-second functional tests using customer-supplied checker boxes
- Final vision check – Bent pin inspection ensures connector quality before product release
- Operator station – Final visual inspection, shake testing, and quality marking
The modular design allows for easy reconfiguration and future expansion. The ceiling mounted dual-robot configuration and integrated reject conveyors ensure smooth material flow throughout the cell maximizing throughput in the compact footprint.
The result – a fully automated microfactory solution
The ANT Plant solution has transformed our customer's ECU production, delivering a complete automation solution that handles all assembly and testing operations in a remarkably compact space of only 4.1 sqm (44.1 sqf). The system manages 14 different applications with two ceiling-mounted robots, demonstrating the exceptional space efficiency of the microfactory concept.
Key achievements include:
- Complete automation from component feeding through final testing
- Compact footprint fitting multiple complex operations in minimal factory space
- Flexible production accommodating multiple product types without tool changes
- 100% traceability with integrated barcode scanning and MES communication
- High-quality output ensured through multiple vision inspections and electrical testing
- Integrated safety with proper guarding and reject handling systems
The modular platform design means our customer can easily adapt the system for future product variations or expand capacity as needed. The combination of advanced robotics, flexible feeding systems, and comprehensive quality verification delivers the consistency and reliability required for automotive-grade electronics manufacturing.
“The ANT Plant concept aligned with our initial goal of implementing a fully autonomous production cell requiring minimal operator intervention while maintaining comprehensive quality and performance checks. The final solution met our needs for assembly, part programming, laser mark identification, testing, and handling of both OK and NG products. JOT’s highly experienced and dedicated project team supported our vision from start to finish and exceeded expectations, developing a strong relationship that has led to current and future projects”, customer’s project lead states.
About the customer
The customer is a leading electronics manufacturer in the USA, supplying advanced electronic control units for the automotive industry. As a Tier 1 supplier, they must meet the highest quality standards while maintaining competitive production efficiency.
If you're looking to automate complex assembly and testing operations in a compact, modular solution, the ANT Plant microfactory platform can help. Get in touch with us to discuss your automation needs.
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