1. Industry Background & Engineering Challenges

Intelligent brake systems are deeply evolving toward brake-by-wire, integration, and intelligence. The core drivers come from the popularization of high-level autonomous driving and new energy vehicles, as well as the extreme pursuit of braking safety, response speed, and energy recovery efficiency.

The continuous emergence of new scenarios brings new challenges to the testing and validation process:

• System architecture validationtransitioning from traditional hydraulic braking to brake-by-wire
• Process transformation validationtransitioning from traditional manual assembly to automated, modular assembly
• Production line flexible adaptability validationfor rapid changeover of multiple product models
• Full-process traceable and quantifiable validationfrom single station to entire production line level

Production line equipment must meet requirements for higher precision, faster cycle time, and lower energy consumption

For OEMs and Tier 1 suppliers, the core issue is no longer “whether a solution exists,” but rather: Can we complete high-quality assembly, testing, and continuous optimization stably, efficiently, and traceably during the mass production phase?

2. KTS System-Level Approach

From the perspective of “building high-quality intelligent brake systems,” KTS has built a comprehensive system covering:

Hydraulic Power Brake System Assembly & Testing Line → Electromechanical Brake System Assembly & Testing Line → Electronic Hydraulic Brake System Assembly & Testing Line → Electric Parking Brake System Assembly & Testing Line → Integrated Brake-Steering HIL Testing

This system is not a single production line but consists of the following three layers of capability:

• High assembly precision and precise force/torque control capability
• Full-station online testing and data traceability capability
• Entire line cycle time optimization and process iteration capability

Ensuring that products are not only “qualified” but also stable, traceable, and usable for production line efficiency improvement and quality.

3. Core Capability Modules
4. Electromechanical Brake (EMB) System Assembly & Testing Line

• Assembly precision and error-proof/leak-proof functionality
• Motor power output and response characteristic testing
• Brake caliper clamping force and release performance validation
• Sensor signal calibration and accuracy testing
• Multi-parameter synchronous acquisition and monitoring including voltage, current, clamping force, and response time

Applicable for:

Electromechanical brake caliper assemblies and components

EMB actuator and control unit (ECU) integrated testing

Full inspection and traceability during mass production line assembly

2. Electronic Hydraulic Brake (EHB) System Assembly & Testing Line

• Assembly precision and error-proof/leak-proof functionality
• Hydraulic circuit sealing and pressure loss testing
• Solenoid valve response characteristic and flow accuracy validation
• Sensor signal calibration and accuracy testing
• Multi-parameter synchronous acquisition and analysis including assist characteristics, pressure build-up rate, and pressure reduction response
• Redundant circuit functionality and failure mode validation

Applicable for:

• Electronic hydraulic brake assemblies and components (EHB/ESC)
• Integrated brake control unit (iBooster+ESC) assembly and testing
• Full-process quality control and data traceability in mass production lines

3. Electric Parking Brake (EPB) System Assembly & Testing Line

• Assembly precision and error-proof/leak-proof functionality
• Parking clamping force and release response time testing
• Motor drive performance and self-locking function validation
• Sensor signal calibration and accuracy testing
• Multi-parameter synchronous acquisition and monitoring including voltage, current, clamping force, and response time
• Simulated validation of hill-hold and emergency release conditions

Applicable for:

• Electric parking brake caliper assemblies and components
• EPB control unit (ECU) and actuator integrated testing
• Full inspection and quality traceability during mass production line assembly

4. System-Level and HIL Joint Testing

• Joint closed-loop testing of brake and steering systems
• Hardware-in-the-loop co-simulation with vehicle control strategies
• Virtual validation of extreme and fault conditions

Applicable for:

• Brake safety validation for high-level autonomous driving
• Functional safety and redundancy strategy validation
• Brake system robustness testing under complex scenarios
• By combining HIL with physical actuation systems, “road test risks” are shifted forward to be completed within the laboratory.

4. Key Technical Advantages

High-flexibility, high-precision assembly execution capability

• Servo and press-fitting systems feature micron-level positioning and torque/pressure error-proofing
• Support mixed-line assembly and rapid changeover of multiple brake caliper and ECU models
• Meet high-frequency mass production cycle time and precision assembly requirements

Multi-station synchronous testing and data traceability

• Synchronous acquisition including torque, pressure, displacement, and signals

Support error-proofing, leak-proofing, online calibration, and real-time quality monitoring

Ensure consistency and traceability of assembly quality for every product

Assembly scenarios can be modeled, reproduced, and optimized

• Support modeling of typical assembly processes and custom procedures
• Full data recording, replayable, and comparative analysis of assembly and testing processes
• Applicable for production line cycle time optimization and process iteration validation

Custom-oriented system integration capability

• Customized solutions based on customer production line layout and capacity requirements
• Support integration of single machines, semi-automated, and fully automated production lines
• Seamless with customer’s existing MES and quality control platforms

5. Typical Application Scenarios

Vehicle manufacturer / Tier 1 brake system assembly and testing

• BYD Co., Ltd., Vie Group
• Complete brake production line planning
• New brake assembly product process development
• Quality and continuous optimization during mass production

6. Implementation & Delivery

KTS provides complete engineering services from requirements analysis to system delivery:

• Requirements and process analysis
• System solution design and simulation validation
• Equipment manufacturing and system integration
• On-site installation, commissioning, and training
• Long-term technical support and system upgrades

7. Selected Case Studies
8. Electronic Hydraulic Brake (EHB) System Assembly & Testing Line

The EHB assembly and testing line is used for the assembly and testing of various components of electronic hydraulic brake systems. It mainly includes a bearing press-fitting machine, large pulley press-fitting machine, ECU and synchronous belt assembly and tension testing machine, magnet block and rivet head assembly machine, screw and input rod sub-assembly machine, NVH testing machine, assist unit performance testing machine, brake unit assembly machine, and assembly performance testing machine.

2. Electromechanical Brake (EMB) System Assembly & Testing Line

The EMB assembly and testing line is used for the assembly and testing of various components of electromechanical brake systems. It mainly includes a bearing press-fitting machine, PPK assembly machine, screw sub-assembly machine, brake caliper assembly machine, parking mechanism assembly machine, NVH testing machine, and assembly performance testing machine.

3. Electric Parking Brake (EPB) System Assembly & Testing Line

The EPB assembly and testing line is used for the assembly and testing of various components of electric parking brake systems. It mainly includes a bearing press-fitting machine, motor assembly machine, ECU assembly machine, planetary gear reduction mechanism assembly machine, brake caliper assembly machine, NVH testing machine, and assembly performance testing machine.

This solution has been successfully applied in multiple brake system assembly and testing projects for various OEMs and Tier 1 suppliers, and has been widely recognized for equipment performance in Measurement System Variation (GRR), operational efficiency, stability, and process adaptability.

8. Contact & Customized Solution

If you are currently developing chassis systems or brake-by-wire chassis-related products, please contact the KTS engineering team. We will provide you with:

• Testing solution recommendations tailored to your specific system architecture
• Customized test system design
• Engineering-level technical communication and support

Get a Technical Solution

Please scan the QR code below or leave a message on our official website. We will arrange for an engineer to contact you promptly, providing detailed technical white papers, successful case studies, and preliminary solution evaluations.

Contact KTS Engineer

Phone: 189 6301 8172