Introduction to the Locked Brushless Motor
The locked brushless motor is a special type of brushless DC motor. In addition to the advantages of high efficiency, long life, and low noise inherent to brushless motors, it also has the capability to hold a fixed position without rotation under specific conditions. The locking feature of the motor is suitable for applications that require precise control.
Explanation of the Locked Brushless Motor Production Line of HONEST Automation
Overall Line Description:
1.Semi-Automation: The production line is designed with semi-automation, combining the strengths of manual operation and automated equipment. It leverages manual transfer of materials between equipment, which is more flexible compared to the automatic feeding methods of machinery.
2.Data Traceability System: The entire production line is equipped with an MES system, which enables monitoring and data traceability of the entire production process, ensuring the traceability of product quality and the convenience of supervision.
Key Production Equipment Overview
A.Core Pressing Machine: Axial Insertion into Rotor Core
Our core pressing machine combines manual core loading with automated axial loading to ensure an orderly material feeding process. The machine’s automatic barcode scanning function quickly identifies QR codes, enabling product information entry and tracking.
The core function of the core pressing machine is the automatic pressing of the axis into the core, ensuring the consistency and accuracy of the pressing. Furthermore, intelligent detection mechanisms such as material presence sensing, axis direction recognition, and pressing pressure displacement curves ensure the precision of each pressing action. Products that fail inspection are manually unloaded and placed in defective product areas.
B.Magnet Insertion Machine
The equipment uses a cylinder to execute the magnet insertion action, ensuring the precision of the insertion. It is also specially equipped with a vacuum cleaner to automatically dust the magnets and rotor, ensuring cleanliness in the production process. Production process data tracking is achieved through product batch numbers, and operator information, facilitating production management.
C.Rotor Riveting, Cleaning, and Magnetizing Machine
The process automates the entire sequence from handling to riveting, cleaning, pressing, and magnetizing. After the product completes riveting and rotor cleaning, it undergoes automatic depression and automatic magnetization with magnetic flux measurement, which effectively increases production efficiency and saves time costs.
By sensing whether the material is in place, monitoring the pressure displacement during the pressing process, and measuring the magnetic flux during the magnetizing phase, each step's completion and quality are ensured.
D.Laser Welding Machine
In the production process, the quality of welding is crucial to the motor's performance. The main function of the laser welding machine is to perform efficient laser welding work. It also includes a protective shield and smoke purifier to ensure the safety of workers and the cleanliness of the production environment.
By conducting spot checks on the tensile strength of the welds, the quality of the welding is ensured to meet production standards. Products that fail inspection are placed in the defective product area by staff, while qualified and defective products are stored separately to ensure the continuity of the production process.
E.Busbar Pressing & Pre-Clamp Shearing Machine
Key Process:
1.The cylinder precisely presses the busbar into place, and the pressure from the cylinder ensures the contact between the busbar and the stator.
2.The stator is transported to the pre-clamping station, where the clamps automatically straighten the copper wire and press the hook against the wire, an automated operation that significantly enhances production efficiency and operational accuracy.
3.When the operator manually moves the product to the shearing station and flips it to have the wire ends facing down, the machine automatically completes the shearing work, ensuring the flatness of the wire ends.
F.Shell & Stator Thermal Assembly & Cooling Machine
The machine automatically transports the shell to the heating station for high-frequency heating, then moves to the pressing station where a servo press is used to press and hold the assembly in place, ensuring proper fitting. The product then automatically moves to the cooling furnace to cool down, ensuring the dimensional stability of the thermally assembled components.
Recording of welding parameters, test parameters, and cycle times facilitates subsequent inspection and management of the production process.
G.Potting & Cooling Machine
The machine features a chain plate oven design, automatically conveying products to the potting station for potting. The automatic potting function can be adjusted according to the potting time required by the product, ensuring uniformity and consistency in the potting process. After the potting operation is completed, the product automatically flows into the cooling chamber, where air cooling is used to control the temperature below 36℃. The exit temperature is monitored to ensure it meets the requirements for subsequent process steps.
Important Inspection Equipment Description
A.Resistance Welding & Performance Testing Machine
After the product is loaded, the machine first scans the product to identify the batch code, ensuring accurate data entry. The equipment supports automatic clamping for welding and automatic conveyance of the product to the welding station, as well as an automatic power supply for testing, ensuring the stability and reliability of the welding process. Further tests on dimensions such as welding time-current curve and welding pressure are conducted to ensure the welding quality meets quality standards.
B.Performance Testing, Air Tightness Testing & Marking Machine
1.Motor Performance Testing: By automatically powering and tightening the nut, the machine observes the working state of the motor to ensure its performance under various operating conditions.
2.Air Tightness Testing: After the product is transported to the air tightness testing station, the equipment automatically seals the product and tests its air tightness to ensure its sealing performance.
3.Product Marking: Once the product is transported to the marking station, the equipment automatically completes the marking process, achieving automation of product identification.
By conducting tests on performance, air tightness, and marking, the consistency and stability of product quality are ensured, reflecting our demand for producing high-quality products.
Reasons for Choosing HONEST Automation as Your Motor Production Equipment Solution Provider:
1.Customized Solutions for Non-Standard Requirements: HONEST Automation is dedicated to offering personalized solutions tailored to our clients' needs. Whether it's production equipment, testing equipment, or specific product manufacturing requirements, we provide customized service to design solutions that fit your actual production needs.
2.High Level of Automation: Our production line has achieved automation in multiple process stages, which not only effectively enhances production efficiency but also ensures the stability and consistency of production quality. We can also provide equipment that operates automatically or manually according to your needs, to adapt to various production scenarios.
3.Defective Product Area: Products that fail inspection during the production process are placed in a designated area for defective items, facilitating the identification and segregation of non-conforming products, thus ensuring the uniformity of product quality.
Additionally, HONEST Automation also offers sample prototyping services for automotive brushless motors to ensure that our designed solutions meet your production requirements. Only after the solution has been verified and the customer is satisfied will it be implemented into production.
If you have any inquiries or needs, please feel free to contact us at any time. Our professional team is ready to assist you, and we eagerly await the opportunity to collaborate with you.
