eVTOL Stator Production Line Production Process Flow (Stator Wire)

Paper insertion and wire embedding station → The top of the stator core teeth is pressed in → Install BUSBAR and TIG welding → Pre paint electrical performance test → Install protective cover and O-ring → Drip paint coating → Preheating and assembly cooling → Install NTC and plastic parts machine → Sealant application → Install carbon fiber shell, screw and rivet → Electrical performance test after painting → Airtightness test → Laser Marking → Dimensional inspection, weighing, and cleaning → Packaging

Technical Requirements

1. Station Cycle Time

Production line cycle/takt time for Rotor: < 275 seconds

Production line cycle/takt time for Stator: < 275 seconds

Single station material handling/replenishment cycle time: < 120 seconds

2. Equipment Operational Rate: &ge; 85%

3. Key Process Characteristics: Cpk &ge; 1.33

4. Critical Equipment: Cmk &ge; 1.67

5. Production Program: Based on 300 working days per year (20 hours per day), double-shift operation, annual output of 66,800 units.

6. Single Equipment Failure Rate: &le; 5%

7. Direct Labor on Production Line: 15 persons

8. Production Line Footprint: 39m (Length) * 8m (Width)

9. Changeover Function & Line Start-up Time: Single station changeover time &le; 30 minutes (No station on the entire line requires a changeover time exceeding 30 minutes).

Main Construction Content

(1) Overcoming Challenges in Tooth Tip Press-Fitting Technology

Leveraging the company's profound technical expertise in the field of precision assembly, we will conduct targeted research and development of specialized press-fitting process technologies. This addresses issues in the electric motor equipment production line for low-altitude aircraft, specifically during the armature pressing phase, such as low efficiency, poor precision, and product deformation. The goal is to overcome core production bottlenecks like unacceptable contour profile after armature tooth tip pressing and high dispersion in press-fit height. By establishing a standardized, highly consistent press-fitting operation system and innovatively integrating an internal support anti-deformation mechanism, we aim to fundamentally solve the deformation problem during the armature pressing process. This will ensure that the armature contour profile consistently meets design standards, strictly control the press-fit height tolerance within 0.1mm, and achieve core dimensional accuracy at an advanced industry level. This strengthens the company's technical barriers in core component manufacturing, lays a solid foundation for the R&D and mass production of subsequent high-end products, and ensures that the equipment, upon successful development, can achieve a post-press tooth tip deviation of less than 0.1mm and cylindrical contour deformation of less than 0.1mm.

(2) Overcoming Magnet Detachment Issues in Post-Magnetization Processes

Building on the company's continuous investment and technological iteration in magnet insertion equipment, we will develop integrated equipment and processes for inserting and pasting magnets. This aims to overcome common industry challenges encountered during the insertion of small magnets, such as insufficient glue quantity, uneven glue layer distribution, glue overflow around the edges, and post-magnetization detachment. Through the coordinated optimization of the glue dispensing system, positioning mechanism, and insertion sequence, the equipment will achieve precise matching and controlled forming of the magnet and glue layer. This will significantly shorten the production cycle, provide critical process assurance for the stable mass production of core components, and consolidate the company's technological advantages in motor manufacturing. The targeted achievements are: magnet insertion product fit less than 0.05mm, and magnet pull-out force greater than 300N.

(3) Overcoming Difficulties in Welding Multiple Types of PIN Wires Combinations

Delving deeply into the field of precision welding technology, we aim to break through the limitations of traditional processes. We will develop combined welding technology for multi-feature Pin wires, enabling efficient integrated welding of Pin wires with different specifications and characteristics. This solves the compatibility challenge of welding complex wiring harnesses and enhances the integration density and structural reliability of components. Concurrently, we will research and develop specialized tooling technology for clamping single sets of copper wires front and back to achieve micron-level precise positioning at the welding station, ensuring high consistency in mass production. Furthermore, we will increase special investment in the field of welding protective equipment, developing integrated welding arc flash protection technology to construct a comprehensive thermal protection barrier. This effectively blocks arc high temperatures and intense light radiation, eliminates the hidden danger of burning the copper wire's insulating varnish, and fundamentally guarantees the electrical insulation safety of the product. This technology aims to achieve welding without burning the varnish or causing bulging, even at a minimum effective welding distance of 4mm.

Product Data

eVTOL Stator Production Line Related Equipment