Automated Assembly and Testing Line for Hydraulic Valve Blocks

For Knorr-Bremse, a global leader in braking systems for commercial vehicles, we designed and delivered a dedicated assembly and testing line for the production of hydraulic filter blocks used in electronic power steering systems.

As this component performs a safety-critical function within vehicle control, the entire process was engineered with maximum emphasis on process stability, repeatability, and quality assurance.

The solution consists of two integrated workstations – an assembly station and a fully automated hydraulic testing station.

1) Assembly Station

The assembly workstation ensures controlled installation and torque-controlled screwdriving of 13 different component types. Due to the variability and complexity of the product, the station is designed as a semi-automated manual workstation, combining operator flexibility with strict process control.

Multi-position fixture - We developed a custom assembly and pressing fixture enabling part manipulation in six different orientations. This solution ensures precise positioning, ergonomic handling, and consistent assembly quality.
Adaptive screwdriving system - Within a single production cycle, six automatic bit changes are performed to ensure the correct torque and tightening sequence for each joint. This guarantees full compliance with the customer’s technical and safety requirements.

2) Automated Hydraulic Testing Station

The second part of the line is a fully automated hydraulic test bench delivered in cooperation with Bosch Rexroth.

Each valve block undergoes comprehensive end-of-line testing, including:

Pressure drop measurement - verification of proper flow characteristics and hydraulic resistance
Leak detection - inspection of both internal and external sealing integrity of every unit
Dynamic testing - measurement of valve opening and closing times in milliseconds

Key Benefits