BYD – Front Axle Assembly Line
Background
As one of the world’s largest EV manufacturers, BYD needed a high-capacity front axle assembly line capable of handling multiple vehicle platforms — from compact sedans to commercial vans — on a single production system.
Challenge
The existing line was optimized for a single platform and required extensive manual changeover when switching between models. BYD sought a flexible, automated solution that could:
- Produce mixed front axle variants with minimal changeover time
- Maintain precision torque control and full traceability
- Fit within the existing factory footprint
- Scale for future platform additions
Solution
Hongbo designed and delivered a complete AGV-based flexible front axle assembly line, integrating:
- Heavy-duty AGV conveyance — Custom fixture-mounted AGVs transport each axle assembly through all stations, enabling free routing and zero mechanical changeover
- Automatic servo tightening stations — Multi-spindle tightening with individual torque and angle monitoring per fastener
- Inline press-fitting cells — For bearing and bushing installation with force-displacement monitoring
- Full MES integration — Every torque value, press curve, and station cycle recorded per axle serial number
The line was pre-assembled and tested in Hongbo’s workshop before shipment, significantly reducing onsite installation time.
Results
- Model changeover time reduced to under 3 minutes (previously 25+ minutes with manual changeover)
- First-time quality rate exceeded 98% within the first month of production
- Annual capacity: 120,000 front axles
- 100% torque and process traceability per axle
- Footprint optimized — 15% smaller than comparable conventional lines
Key Equipment Delivered
- Heavy-duty AGV system with custom fixtures
- Multi-spindle servo tightening stations
- Bearing press-fitting cells
- Inline gap and presence detection
- MES workstation with real-time dashboard