1. Fully Automated Workflow

The line covers complete processes including:

▪ Mirror assembly

Lens loading / Film removal / Cleaning / Bonding

▪ Stator assembly

Core loading / Winding / Tin dipping / Performance testing

▪ Rotor assembly

Magnet ring installation / Encoder disk bonding / Bearing press-fitting

▪ Motor final assembly

Stator-rotor assembly / Wave spring and retaining ring assembly / Dynamic balancing inspection

This helps simplify production and reduce dependence on manual labor.

2. High-Precision Manufacturing Assurance

Critical processes are based on servo control + vision-guided positioning, with key precision targets including:

▪ Repeat positioning accuracy: ≤ ±0.01 mm

▪ Lens bonding angle accuracy: 90° ± 0.025°

▪ Included angle between four glass surfaces: ≤ 90° ± 0.02°

▪ Press-fit force accuracy: ±5%

▪ Displacement accuracy: ±0.01 mm

3. High Production Efficiency

The line is optimized for large-scale batch production, with:

▪ Line UPH: ≥ 300 pcs

▪ Stable OEE

▪ Strict cycle time control for critical processes (for example, CT ≤ 2.5 s per laser weld point)

Its annual output capability is suitable for large-volume manufacturing requirements.

4. Full-Process Error-Proofing and Traceability

The line integrates multiple control and poka-yoke mechanisms, including:

▪ Torque traceability

▪ Vision inspection

▪ Material recognition

▪ Missing-part detection

The error-proofing rate reaches 100%.

All stations are connected to the MES system, enabling full-process traceability of:

▪ Production data

▪ Process parameters

▪ Quality inspection results

5. Safety and Clean Manufacturing Configuration

▪ Welding stations are equipped with dedicated fume extraction systems

▪ High-temperature equipment includes multiple temperature sensors

▪ The equipment complies with ESD protection requirements

▪ The operating environment meets Class 1000 cleanroom standards

▪ Noise level: ≤ 70 dB (measured at a distance of 1 meter from the line)

1. Mirror Assembly

▪ Lens loading

▪ Film removal and cleaning

▪ Plasma cleaning of rotor base (water contact angle after cleaning: ≤ 20°)

▪ Adhesive dispensing (using dedicated adhesives such as Delu LA4880)

▪ UV pre-curing

▪ Lens bonding (pressure holding for 1 minute)

▪ High-temperature curing (105°C / 12 h)

▪ Pitch angle / dihedral angle inspection

▪ Surface profile inspection

2. Stator Assembly

▪ Core loading

▪ Six-station winding (wire diameter 0.18 mm, turns 50T)

▪ Tin dipping

▪ Shaft core press-fitting

▪ Winding performance testing (resistance, withstand voltage, insulation, turn-to-turn, inductance)

▪ PCB locking

▪ Terminal welding

▪ UV curing

3. Rotor Assembly

▪ Magnet ring adhesive dispensing

▪ Magnet ring press-fitting

▪ Encoder disk bonding

▪ Baking and curing (80°C / 20 min)

▪ Bearing press-fitting

▪ Encoder disk cleaning and functional testing

4. Motor Final Assembly

▪ Stator-rotor assembly

▪ Bearing press-fitting

▪ Wave spring, metal washer, and retaining ring assembly

▪ Standing cure

▪ Dynamic balancing inspection (speed 150 &plusmn; 1 rpm, unbalance < G2.5)

▪ Motor performance testing

▪ NVH testing (noise &le; 30 dB, vibration &le; 0.2 m/s&sup2;)

▪ Protective film application and unloading

1. Applicable Product Parameters

▪ Lens bonding precision

Angle between glass surface and top surface: 90&deg; &plusmn; 0.025&deg;

Included angle between four glass surfaces: 90&deg; &plusmn; 0.02&deg;

▪ Winding parameters

Wire diameter: 0.18 mm

Turns: 50T

Three-phase lead / tail length: &ge; 35 mm

▪ Dynamic balancing requirement

Speed: 150 &plusmn; 1 rpm

Unbalance: < G2.5

▪ NVH targets

Noise: &le; 30 dB (test distance 10 cm, 0&ndash;200 kHz)

Vibration: &le; 0.2 m/s&sup2; (0&ndash;200 kHz)

2. Core Equipment Parameters

▪ Air pressure requirement: &ge; 0.65 MPa (automatically detected and uploaded to MES)

▪ Power supply: 380 V &plusmn;10%, frequency 50 Hz &plusmn;5%

▪ Working environment

Temperature: 5&deg;C to 45&deg;C

Relative humidity: 30% to 80%

Class 1000 cleanroom environment at critical assembly stations

▪ Equipment footprint

Line depth: &le; 3500 mm

Operating height: 900 &plusmn; 50 mm

▪ ESD protection

Surface resistance of equipment materials: 1 &times; 10⁵ &Omega; to 1 &times; 10⁹ &Omega;

Triboelectric voltage: < 100 V

3. Inspection Accuracy Parameters

▪ 2D camera accuracy: &le; 0.1 mm/pixel

▪ Field of view: &ge; 160 mm &times; 160 mm

▪ Dynamic balancing machine minimum test accuracy: < 1 mg

▪ Correction accuracy: &le; 1 mg

▪ Electrical performance testing

Phase-to-phase resistance: TBD &plusmn;10%

Phase inductance: TBD &plusmn;7%

Inter-turn waveform area difference under AC800V / 1s: &le; 10%

1. Mirror Assembly Equipment

Lens Bonding Mechanism

▪ Uses vacuum adsorption + electric cylinder drive

▪ Equipped with pressure and displacement sensors

▪ Prevents lens damage caused by excessive pressure

▪ Pressure holding time: 1 minute

Plasma Cleaning Machine

▪ Inline 360&deg; rotating cleaning

▪ Prevents empty-shot alarms

▪ Water contact angle after cleaning: &le; 20&deg;

▪ Includes exhaust gas recovery treatment

High-Temperature Curing Oven

▪ Temperature range: RT +20&deg;C to +200&deg;C

▪ Temperature control accuracy: &plusmn;2&deg;C (no-load)

▪ Equipped with 3 or more temperature sensors for cross-verification

▪ Data uploaded to MES

2. Stator Winding Equipment

Six-Station Winding Machine

▪ Supports wire diameter: 0.05&ndash;0.2 mm

▪ Compatible with 720-turn switching

▪ Automatic tension control

▪ Wire break detection alarm

▪ Editable and storable winding programs

Winding Performance Tester

Supports five test items:

▪ Resistance

▪ Withstand voltage

▪ Insulation

▪ Turn-to-turn

▪ Inductance

It also supports automatic code scanning and defective product lockout alarm.

3. Rotor Assembly Equipment

Servo Press Machine

▪ Rated force: &ge; 10 kN

▪ Force resolution: 1 N

▪ Sampling rate: 1000 times/second

▪ Pressure holding time: 0&ndash;60 s adjustable

▪ 100% pressure / displacement monitoring

Encoder Disk Inspection Equipment

Detects:

▪ Zero position

▪ Code track line count

▪ Signal jitter

and meets Class 1000 cleanroom environment requirements.

4. Inspection Equipment

Automatic Angle Measuring Instrument (Collimator)

▪ Resolution: 0.1&Prime;

▪ Accuracy: &plusmn;1&Prime;

▪ Repeatability: 0.5&Prime;

▪ Used for pitch angle / dihedral angle measurement

Laser Interferometer

▪ Light source: 632.8 nm

▪ Camera resolution: 2K &times; 2K

▪ PV repeatability: < &lambda;/500

▪ Used for lens surface profile testing (PV < 2.5 &mu;m)

Dynamic Balancing Tester

▪ Minimum test accuracy: < 1 mg

▪ Allowable speed: &ge; 5000 r/s

▪ Supports test &ndash; correction &ndash; retest workflow