The rapid penetration of new energy vehicles is reconfiguring the vehicle horn industry pattern. Data show that in 2025 the domestic vehicle horn market size will exceed 15.2 billion yuan, of which the new energy vehicle supporting horn sales growth rate of 43%, the electronic horn has jumped to 53% from 37% in 2020. the depth of the integration of the intelligent cockpit and the ADAS system, the horn's magnetic circuit precision, acoustic consistency put forward harsh requirements, the traditional artificial assembly mode is encountering bottlenecks. The traditional manual assembly mode is encountering a bottleneck.

The core challenges of car speakers are centered on the assembly of the magnetic circuit system and the calibration of acoustic performance. The uniformity of the magnetic gap directly affects the distortion rate, and new energy vehicles require speakers with a distortion rate of less than 3%, so it is difficult to maintain a magnetic gap tolerance of ±0.05mm in manual assembly. At the same time, smart speakers need to integrate MCU chips and acoustic algorithms, and the error rate of coordinated assembly of multiple components climbs with complexity. Data from a host factory shows that the defective rate of manual production line is as high as 2.3%, of which 70% originates from the misalignment of the magnetic circuit and lead wire soldering.

The automated production system solves the problem through three technological breakthroughs. In the assembly of magnetic circuit, electromagnetic adsorption limit and high-precision guide roller technology are adopted to ensure that the alignment deviation of NdFeB magnet and T iron is controlled within ±0.02mm, which is 3 times more accurate than manual. In the voice coil winding stage, the servo system regulates the tension of copper wire in real time, and with AI visual inspection to identify the risk of wire breakage, the qualification rate of winding wire is increased from 95% to 99.8%. The most critical is the acoustic online inspection module, with the built-in Klippel analyzer, which can complete the frequency response and impedance test in 3 seconds, and the data is synchronized with the MES system automatically to realize the traceability of 100%. Traceability.

After a Yangtze River Delta enterprise introduced this program, the production beat of the car smart speaker was shortened from 45 seconds / only to 32 seconds / only, the labor cost was reduced by 52%, and more importantly, it passed the ISO 7188 band standard certification, and successfully entered the supply chain of new energy vehicle front-end installations. This proves that automation is not only an efficiency tool, but also the core support for technology upgrade.