The Process of the Automated Production Line for Automotive Permanent Magnet Motors
The automated production line for automotive permanent magnet motors integrates advanced processes and equipment to manufacture high-quality motors efficiently. Key steps include precise magnet insertion and injection molding for rotor manufacturing, stamping and winding insertion for stator production, and final assembly with dynamic balancing and EOL testing. Utilizing 3D vision-guided robots, laser marking, and automated conveyance systems, this line ensures high precision, flexibility, and efficiency. It meets the stringent demands of the automotive industry for performance and reliability, supporting the production of various motor models with consistent quality.
Process of the Automated Production Line for Automotive Permanent Magnet Motors
1. Process Flow
The automated production line for automotive permanent magnet motors includes several key steps:
- Rotor Manufacturing
- Inserting Permanent Magnets into Stator Cores: Accurate placement of permanent magnets into the rotor cores.
- Injection Molding: Fixing the magnets in place with injection molding.
- Heating and Curing: Solidifying the molding material through heating to securely hold the magnets.
- Stacking Rotor Cores: Assembling multiple rotor cores to form a complete rotor.
- Dynamic Balancing: Testing and adjusting the rotor for dynamic balance to ensure smooth rotation.
- Magnetization: Charging the permanent magnets to make them magnetic.
- Surface Magnetism Detection: Checking the surface magnetic field strength of the permanent magnets to ensure they meet requirements.
- Press Fitting: Assembling the rotor onto the rotor shaft with high precision.
- Laser Marking: Marking production information on the rotor for traceability and management.
- Stator Manufacturing
- Stator Core Stamping: Manufacturing stator cores through stamping to ensure precise dimensions.
- Winding Insertion: Inserting flat or round wire windings into the stator cores to ensure electrical connections.
- Insulation Treatment: Applying insulation treatment to the windings to ensure electrical performance.
- Stator Assembly: Assembling the windings and cores into a complete stator to ensure structural stability.
- Motor Final Assembly
- Housing Assembly: Assembling the motor housing with the stator, rotor, and other components to form a complete motor.
- Bearing Installation: Installing front and rear bearings to ensure free rotation of the rotor.
- End Cover Installation: Installing end covers to protect internal components.
- Terminal Box Installation: Connecting the motor windings to the external power supply to ensure electrical connections.
- Final Testing: Conducting End of Line (EOL) tests to ensure the motor meets performance standards.
2. Automated Production Line
The automated production line for automotive permanent magnet motors typically includes the following equipment and systems:
- Conveying System: Using belt conveyors or AGV carts for automatic feeding to achieve automated transmission of components.
- 3D Vision-Guided Robots: Used for automatic positioning and assembly of components to improve assembly accuracy.
- Automatic Tool End Loading: Achieving automatic tool changing and loading to improve production efficiency.
- Dynamic Balancing Equipment: Conducting high-precision dynamic balancing tests on rotors.
- Magnetizing Equipment: Charging permanent magnets with precision.
- Laser Marking Equipment: Marking production information on the rotor or motor housing.
- EOL Testing System: Conducting final performance tests on assembled motors.
3. Technical Parameters Table
| Process Step | Main Equipment | Function |
|---|---|---|
| Rotor Manufacturing | Magnet Insertion Equipment | Inserting permanent magnets |
| Injection Molding Equipment | Fixing with injection molding | |
| Heating and Curing Equipment | Heating and curing | |
| Dynamic Balancing Equipment | Dynamic balancing | |
| Magnetizing Equipment | Magnetizing | |
| Laser Marking Equipment | Marking production information | |
| Stator Manufacturing | Stamping Equipment | Manufacturing stator cores |
| Winding Insertion Equipment | Inserting windings | |
| Insulation Treatment Equipment | Insulation treatment | |
| Motor Final Assembly | Housing Assembly Equipment | Assembling motor housing |
| Bearing Installation Equipment | Installing bearings | |
| End Cover Installation Equipment | Installing end covers | |
| Terminal Box Installation Equipment | Connecting windings to power supply | |
| EOL Testing Equipment | Final performance testing |
4. Advantages
- High Precision: Achieved through 3D vision-guided robots and high-precision testing equipment to ensure precise assembly of components.
- High Efficiency: The automated production line reduces manual intervention, increasing production efficiency.
- Flexibility: The production line can adapt to the production of various motor models, meeting the needs of different customers.
- High Quality: Ensured through the EOL testing system, which guarantees that each motor meets performance standards.
5. Application Case
A well-known new energy vehicle manufacturer has adopted an automated process for the rotor assembly line of electric motors, including magnet assembly, injection molding, cleaning, press fitting, dynamic balancing, and EOL testing. This has enabled the co-production of induction motors and permanent magnet synchronous motors, significantly improving production efficiency and product quality.
Through the above processes and equipment, the automated production line for automotive permanent magnet motors can achieve efficient and high-precision production, meeting the demand for high-performance motors in new energy vehicles.