Automated Machining Case for Electric Drive / Differential Housings

In the manufacturing of new energy vehicle components, die-cast housings for electric drives and differentials are core power parts, which directly affect the transmission efficiency and operational stability of complete vehicles. These aluminum alloy die castings feature complex structures, multiple cavities and dense hole positions, with high requirements on position tolerance, concentricity and surface finish.

Many manufacturers of auto parts are facing common challenges during mass production. Manual loading and unloading leads to low efficiency. Split multi-process machining tends to cause inconsistent dimensions and fluctuating yield rates, making it difficult to meet strict supply audit standards of major OEMs and restricting the improvement of both production capacity and product quality.

To address the precision mass-production challenges of new energy die-cast housing parts, Beijing Smart provides turnkey services including DN high-end machine tools, custom automation integration and full-process support. We build fully automatic precision production lines for electric drive housings and differential housings to help manufacturers achieve efficient, stable and standardized mass production.

Workpieces in Project

Aluminum alloy die-cast differential housings and electric drive assembly die-cast housings for new energy vehicles

Machining Pain Points

1. The workpiece has complex internal cavity structures with multiple holes and steps, requiring strict position tolerance and bringing high machining difficulty.
2. Separated processes and heavy manual intervention easily introduce human errors, making it hard to guarantee product consistency.
3. Fluctuating yield in mass production makes it difficult to meet the qualification requirements for mass supply to OEMs.
4. Unstable manual loading/unloading restricts production capacity and cannot match the delivery demand of large-batch orders.

Implementation Solution

Combined with workpiece process characteristics and mass production requirements, this project adopts PUMA series turn-mill machining centers as core equipment, paired with 6-axis robot flexible automation units to build a closed-loop unattended production line.

The equipment supports multi-process composite machining. One-time clamping can complete turning, milling, drilling, tapping and fine boring of housings, reducing cumulative errors caused by repeated clamping. Custom dedicated hydraulic fixtures are equipped to fit the special-shaped housing structure, ensuring stable clamping and lowering the risk of workpiece deformation.

The production line integrates on-line dimension inspection and automatic error compensation system. The whole workflow including blank loading, precision machining, deburring, dimension re-inspection and finished product unloading can be automatically completed with reduced manual intervention.

Project Outcomes

• Stable and controllable quality: Automated machining reduces human errors. The dimensional consistency of parts is greatly improved, and the yield meets standards. The production successfully passed the supply chain audit of major new energy vehicle manufacturers.
• Greatly increased production capacity: Unattended continuous production raises single-shift capacity by 60%, easing capacity bottlenecks caused by manual operation.
• Obvious cost reduction and efficiency improvement: Reduced labor investment cuts labor and management costs, supporting 24-hour non-stop mass production.
• Strong adaptability for mass production: The line supports model changeover for multiple housings of the same series, flexibly matching iteration demands of vehicle models.

Solution Advantages

We provide not only equipment supply, but also full-process process delivery. Our one-stop turnkey service covers preliminary process review, custom fixture & cutting tool design, program commissioning, mid-term line integration and trial cutting verification, as well as post-launch training and after-sales maintenance. We help customers achieve rapid project rollout and stable mass production.

If you need planning of automated production lines, process upgrading or turnkey project implementation for new energy die-cast housings and precision auto parts, please contact Beijing Shenming Technology. Our engineers will customize exclusive mass-production solutions one-on-one.