1. Fully Automated Workflow

The line covers complete processes including:

▪ Core loading

▪ Laser marking

▪ Magnet insertion

▪ Injection molding

▪ Stack assembly and riveting

▪ Rotor cleaning

▪ Dynamic balancing

▪ Magnetization and inspection

This helps simplify production and reduce dependence on manual labor.

2. High Flexibility for Multiple Rotor Specifications

By changing tooling and molds, the line is compatible with a wide range of products:

▪ EM1 series

Core outer diameter: 100–180 mm

Rotor height: 30–120 mm

▪ EM2 series

Core outer diameter: 150–240 mm

Rotor height: 30–110 mm

It also supports multiple magnet slot types, including:

▪ V type

▪ Double V type

▪ V + I type

3. High Production Efficiency

The line is optimized for large-scale batch production:

▪ Line cycle time: ≤ 120 seconds

▪ Annual capacity per line: 150,000 sets

▪ Equipment uptime: ≥ 85%

▪ MTBF: ≥ 30 hours

4. Precision Manufacturing Assurance

Key processes are servo-controlled, enabling precise control of:

▪ Stack assembly and riveting

▪ Dynamic balancing

▪ Magnetization and inspection

Performance targets include:

▪ First-pass yield: ≥ 98% (excluding welding rework)

▪ Scrap rate: ≤ 0.5%

▪ Process capability index (cmk): ≥ 1.33 (sampling n ≥ 50)

5. Convenient Changeover

Changeover for products within the same series is completed through simple tooling replacement and program switching.

▪ Changeover time: < 30 minutes

This makes the line suitable for multi-variety, small-batch production.

6. Full Traceability

The line is integrated with an MES system, using technologies such as:

▪ Barcode scanning

▪ RFID

to achieve full traceability of materials, process parameters, and quality data, while also supporting production data analysis and statistics.

1. Core Loading

▪ Manual-assisted core placement on loading trolley

▪ Robot picking and product information scanning

▪ Accurate placement onto line fixture carrier

2. Laser Marking

▪ Automatic QR code marking on core end face

▪ Marking grading and data upload to MES

▪ Equipped with smoke purification device

3. Magnet Insertion

▪ Operator places magnets into tray

▪ Robot accurate insertion into magnet slots

▪ Automatic insertion quantity checking

4. Injection Molding

▪ 85T injection molding machine, one-in one-out

▪ Rotor core molding process

▪ Injection quantity confirmation by weighing

5. Stack Assembly and Riveting

▪ Manual loading of shaft, hub, balancing plate and core

▪ Automatic press-fitting and six-point riveting

▪ Avoids slot positions to ensure dimensional accuracy

6. Marking and Cleaning

▪ Secondary laser marking

▪ Air knife surface cleaning

▪ Dust collector for debris removal

7. Dynamic Balancing

▪ Six-axis robot rotor handling

▪ Automatic drilling for material removal

▪ Burr-free after correction

8. Magnetization and Inspection

▪ Automatic robot loading and unloading

▪ Saturated magnetization in magnetizing coil

▪ Magnetic flux and surface magnetic field testing

▪ OK/NG signal output

1. Applicable Rotor Parameters

▪ EM1: OD 193.2 mm, core 100&ndash;180 mm, H 30&ndash;120 mm

▪ EM2: OD 131.48 mm, core 150&ndash;240 mm, H 30&ndash;110 mm

▪ Slot count: 36&ndash;96, copper wires per slot: 4&ndash;12

▪ Rotor assembly weight: &le; 50 kg

2. Production Efficiency

▪ Line cycle time: &le; 120 seconds

▪ Annual capacity: 150,000 sets/line

▪ Workstation cycle imbalance: < 20%

3. Utility Requirements

▪ Air pressure: 0.4&ndash;0.6 MPa

▪ Power: 380 V&plusmn;10%, 50 Hz&plusmn;10%, 3P5W TNS

▪ Temp: -5&deg;C to 45&deg;C, humidity &le; 85%

▪ Noise: &le; 80 dB(A)

4. Layout & Dimensions

▪ Single line: 15.5m &times; 12.6m = 195.3㎡

▪ Total area: 33.4m &times; 12.6m = 476㎡

1. Core Loading and Transfer Equipment

▪ 3 loading trolleys for efficient manual feeding

▪ Servo-controlled pick-and-place robot

▪ Lifting positioning and circumferential alignment

2. Laser Marking Equipment

▪ 100W laser controller, depth &ge; 0.25 mm

▪ Grade B or above qualified, with calibration samples

▪ 2000m&sup3;/h smoke purifier, PM0.1&mu;m filtration

3. Magnet Insertion Machine

▪ Auto tray switching, 2-hour material supply

▪ Four-axis robot, positioning accuracy 0.02 mm

▪ Missing magnet detection and batch traceability

4. Stack Assembly and Riveting Equipment

▪ Four-column guide-post press-fit structure

▪ Pressure-displacement curve monitoring

▪ Six-point uniform riveting, quick-change mold

5. Dynamic Balancing Equipment

▪ Six-axis robot, movement accuracy 0.02 mm

▪ Automatic drilling correction, dust collection

▪ Quick changeover within 0.5 hours

6. Magnetization and Inspection Equipment

▪ 200&ndash;4500 VDC, max 30 kA output

▪ Cycle &le;110s, resolution 0.01 mT

▪ Flux meter 0&ndash;1 Wb, accuracy &plusmn;0.4%