In the global wave of transformation toward high-level autonomous driving, Brake-by-Wire (BBW) has emerged as the core of intelligent chassis. However, the high-precision press-fitting of valve body assemblies remains a critical bottleneck for Tier 1 suppliers’ capacity and quality. With over a decade of technical expertise in precision assembly, Leetx has cumulatively delivered over 200 servo presses to a leading Chinese Tier 1 intelligent chassis manufacturer between 2022 and 2025. These units cover all press-fit and steel-ball sealing stations for BBW valve assemblies. In this bellwether market for global New Energy Vehicle (NEV) innovation, Leetx successfully resolved the paradox between "high cycle time" and "high precision" through its proprietary "Automatic Speed Reduction" and "High-Precision Inflection Point Capture" technologies, ensuring the high-yield operation of the customer's production lines.
Brake-by-Wire is a foundational component for achieving high-level autonomous driving and is currently in an explosive growth phase. Industry forecasts suggest that BBW penetration in China’s passenger car market will reach 65% by 2025 and is expected to hit 95% by 2030. Under this trend, leading Chinese suppliers are aggressively expanding capacity, placing stricter demands on upstream assembly equipment regarding cycle time, precision, and process control capability.
The valve body assembly is the focal point of assembly difficulty in BBW systems. A single valve block integrates multiple solenoid valves and steel-ball sealing points, requiring sequential multi-station press-fitting within a tight cycle time. Simultaneously, the process must achieve real-time interception of anomalies such as overstroke, misalignment, and missing parts. Even a minor deviation can compromise the sealing integrity and functional reliability of the braking system.
The customer is a leader in the Chinese intelligent chassis industry. Their BBW products have achieved large-scale adoption by multiple mainstream automakers, with shipment volumes holding a leading position among Chinese domestic brands. At their core production facility, the valve press-fit process faced four central challenges:
Stringent Cycle Time: Single-station press-fitting must be completed in an extremely short window without sacrificing quality control for output efficiency.
Strict Yield Management: With dense sealing points, there are explicit metrics for pressing force control, displacement accuracy, and incoming material consistency.
Mandatory Real-time Interception: Issues such as overstroke, misalignment, and missing parts must be identified during the process to trigger protection, ensuring zero damage and zero defects.
Consistency in Large-scale Delivery: Once a fleet of equipment is deployed, inter-machine consistency must be maintained to avoid quality fluctuations introduced by equipment variance.
Based on the customer's process requirements, Leetx developed and deployed core functions around the servo press system:
① Automatic Speed Reduction — Resolving the "Fast vs. Accurate" Conflict The system maintains high speed during the rapid approach phase to meet cycle time requirements. When the pressure curve reaches a preset threshold, it automatically switches to a low-speed precision control mode, ensuring the final seating is reached without overstroke. This effectively reduces the risk of product damage caused by over-pressing without sacrificing throughput.
② High-Precision Inflection Point Capture — Supporting Material Consistency Monitoring Integrated with absolute position encoders and high-precision pressure sensors (24-bit resolution, 10 kHz sampling frequency), the system achieves precise capture of the inflection point on the force-displacement curve. The customer can use this to monitor fluctuations in incoming material consistency and intercept abnormal parts during the assembly process, driving yield improvements.
③ Real-time Anomaly Monitoring and Protection Mechanisms The entire press-fit process is compared in real-time against preset evaluation windows, covering anomalies such as overstroke, misalignment, and missing parts. Any trigger results in an immediate machine stop to prevent the outflow of defective products. Every press-fit operation is fully traceable.
The continuous delivery of these 200+ units over four years is more than just a milestone for Leetx in the Chinese market; it is a "high-pressure rehearsal" completed within one of the world's most competitive manufacturing environments. It deeply validates the large-scale deployment capability of Leetx servo press systems under extreme cycle time and precision requirements, transforming reliability from a slogan into quantifiable performance.
Notably, Leetx's proprietary "Automatic Speed Reduction" and "High-Precision Inflection Point Capture" technologies have evolved from bespoke customer requirements into general-purpose technical solutions for the Brake-by-Wire industry. Through this evolution, Leetx has accumulated profound process expertise and a mature large-scale delivery framework. Standing on this foundation, we are ready to support global Tier 1 suppliers in moving toward the era of "zero-defect" mass production for intelligent chassis.
Learn more: www.leetx.com/en
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