[Case Title]
The Ten Year Exam Paper for a Smart Door Lock - A Full Life Cycle Documentary of ASLONG JGA25-310 in a Global Leading Smart Door Lock Brand
[Case Time]
2022.04 demand approval → 2022.11 first round of DVT → 2023.06 mass production launch → 2025.09 global shipment exceeds 1.2 million units
[Project Background]
In 2022, a global top 3 smart door lock brand (hereinafter referred to as "L Company") plans to launch its flagship new product, the "Silent Fully Automatic Push Pull Lock P9", in 2023. This lock imposes four "limit" requirements on the drive motor:
The body thickness is ≤ 21 mm, leaving only 25 mm × 37 mm of space for the motor;
Unlocking thrust ≥ 6 kgf, and must pass a 45 dB night test with 100% silence;
100000 cycles with zero failures, equivalent lifespan ≥ 1500 hours;
The delivery cycle is 90 days, and the cost needs to be 15% lower than the previous generation of 37mm motors.
L company has tested 6 international first-line brand motors, but none of them met the standards. Eventually, ASLONG JGA25-310 was selected and a customized version was jointly developed.
[Solution]
Structural customization
The length of the motor has been compressed from the standard 37 mm to 34 mm;
Change the output shaft to D-cut 5 mm × 10 mm, directly insert it into the lock body clutch sleeve, cancel the coupling, and reduce the thickness by another 1.8 mm.
Performance Upgrade
The gear set has been upgraded from powder metallurgy to 45 # steel gear hobbing+vacuum carburizing, with a surface hardness of HRC 58;
Rare earth magnetic tile magnetic flux density increased by 12%, peak torque reached 15 kg · cm, and no-load noise was ≤ 42 dB (measured by L company at 38 dB);
Using full ball bearings and food grade grease, the laboratory can operate continuously for 2000 hours without wear under a load of 3 kg · cm.
quality control
ASLONG and L company jointly establish an IQC joint laboratory, with 100% online testing of tooth profile, magnetic flux, noise, and push-pull force;
Introduce SPC process statistics, CPK ≥ 1.67；
Randomly select 20 units from each batch for 100000 cycles of accelerated aging, and release them only after all zero failures.
【 Implementation results 】
The new P9 will be launched in June 2023, with 180000 units sold in the first month;
In December 2024, a total of 1.2 million units were shipped globally, with a repair rate of only 0.02% after sales;
In September 2025, L Company will include JGA25-310 as a standard component for the next generation of "ultra-thin silent lock" platform, with an expected increase of 6 million orders within 3 years.
Customer Testimony
In the past, we used 37 mm motors from European brands, which were bulky, noisy, and expensive. JGA25-310 achieved a torque of 15 kg · cm and 38 dB noise within a size of 25 mm, directly increasing our overall thickness from 28 mm to 20 mm and reducing costs by 12%. Passing 100000 life tests in one go is the most hassle free collaboration we have encountered in the supply chain. ”
——David Zhang, Senior Director of Hardware at L Company
ASLONG Viewpoint
The ASLONG project leader stated that the success of JGA25-310 is not simply about replacement, but about redefining the four conflicting indicators of 'size, torque, noise, and lifespan' together with the customer. In the future, we will replicate this joint development model to more smart home scenarios, making 25mm the new industry gold size