Leading NEV Maker Launches Fully Automated Smart Cockpit Domain Controller Test Line

A leading domestic new energy vehicle manufacturer faced dual challenges of high product complexity and tight delivery timelines during mass production of its next-generation intelligent cockpit domain controller (DCU). Traditional testing approaches struggled to meet requirements for efficiency, consistency, and reliability. The DCU required comprehensive multi-dimensional testing—including burn-in, RF, functional, and human-machine interaction tests. The previous decentralized process suffered from redundant steps, uneven production line pacing, heavy reliance on manual labor, and inconsistent test results. Given stringent reliability requirements, any oversight in testing could trigger significant batch quality risks. To address these issues, a customized end-to-end automated testing line for the intelligent cockpit DCU was deployed. This line covers the complete workflow—from burn-in to visual inspection: Burn-in → Cooling → RF Testing → Vibration → Functional Testing (ATE) → End-of-Line Testing (EOL) → Labeling → Touchscreen HMI Interaction → Automated Optical Inspection (AOI). Featuring a highly integrated architecture, the line consolidates heterogeneous stations—including RF, ATE, EOL, HMI, and AOI—minimizing manual intervention. A parallel testing strategy optimizes cycle time, achieving a stable throughput of 60 seconds per unit. Automated barcode scanning, serial number binding, and automatic test program matching have reduced operator headcount from 12 to 3. All test data is automatically uploaded to the MES system, enabling First Pass Yield (FPY) and Statistical Process Control (SPC) analysis for rapid traceability and closed-loop quality improvement. The automated testing line is now stably operational at the customer site, supporting large-scale DCU production and significantly enhancing test consistency and stability.