In contemporary automotive design, the driving experience is a significant consideration. The sunroof, as an important feature that enhances interior lighting and improves ventilation conditions, directly affects passenger comfort. The sunroof motor, which enables the opening and closing movement of the sunroof, plays a pivotal role in its functionality.
Working Principle of the Sunroof Motor
Sunroof motors typically utilize direct current (DC) motors, which operate based on Faraday’s law of electromagnetic induction. When an electric current passes through the coil, the coil experiences a force within the magnetic field, causing it to rotate. The motor receives electrical signals from the sunroof control unit, converting electrical energy into mechanical energy to drive the reducer and transmission mechanism, thereby facilitating the opening and closing of the sunroof.
Parameters for Assessing Sunroof Motor Performance Primarily Include:
1.Torque: The force exerted by the motor’s output, affecting the strength of the sunroof’s opening and closing;
2.Speed: The rotational velocity of the motor, influencing the speed of the sunroof’s movement;
3.Operating Voltage: The voltage range required for the motor’s normal operation;
4.Temperature Range: The lowest and highest temperatures within which the motor can function properly;
5.EMC Level: The electromagnetic compatibility of the motor ensures it does not interfere with other electronic devices in the vehicle.
HONEST Automation’ Sunroof Motor Assembly Line
1.The production line includes the armature assembly section, motor assembly section, magnetic base assembly section, gearbox assembly section, and gearbox testing section.
2.Layout Design: The overall design of the production line combines an efficient assembly line with flexible single-machine equipment, achieving rapid production rhythm, high output, quick model changeover, and ease of process adjustment and expansion.
Key Details of Some Critical Process Steps are as Follows:
A. Armature Assembly Section
1. Automatic Spot Welding Machine: Utilizing direct current inverter welding technology, coupled with an automatic monitoring system, ensures the quality of the welding. The system can automatically detect welding power, and will automatically alert in case of poor electrical connection or power exceeding specifications. Defective products are automatically directed to the defective product area to prevent production interruptions.
2. Resistance Waveform and Electric Current Test Machine: Equipped with advanced testing instruments, it automatically tests the armature’s resistance, voltage endurance, and short circuit conditions. Defective products are automatically ejected, and the equipment will automatically alert if there is a continuous defect. Additionally, a dual-station test seat is configured to improve model change efficiency.
3. Copper Brushing Machine: After turning, copper brushing treatment is carried out to clean the commutator turning surface and the gap between the copper pieces. The brushing time with the brush can be adjusted according to the customer's actual production conditions to meet different production needs.
4. CCD Inspection Equipment: Using a high-precision CCD visual inspection system, it automatically inspects whether there are any foreign objects in the turned commutator copper sand, the precision of the winding flying wire, and the rebalancing groove, with non-compliant products automatically directed to the defective product area.
B. Magnetic Base Assembly Section
1. Automatic Glue Application: The robotic arm automatically grasps the iron shell and applies glue at the designated position of the glue head. This automated operation not only facilitates the adjustment of the amount of glue but also promotes manual material replacement when the glue quantity is low, ensuring continuous production while improving efficiency.
2. Magnetic Base Dust Removal: The magnetic base cleaning is carried out using a blow-suction method, effectively ensuring the cleanliness of the production process and preventing the impact of dust and impurities on product quality.
3. Precision Inspection: While the magnetic base passes through the internal diameter base check for stoppage, a pressure sensor is configured to detect the thrust of each piece of magnet. Any magnetic base that does not meet the standard is automatically ejected. Moreover, the CCD visual inspection system automatically checks for any poor grease application, with defective products also automatically directed to the defective product area, ensuring that each magnetic base meets the quality standard.
C. Motor Assembly Section
1. No-load Current and Speed Test: Specialized testing equipment is utilized to precisely measure the no-load current and speed of the motor, ensuring that the motor’s performance under no-load conditions meets the required standards.
2. High Level of Automation: The motor assembly section has achieved a high degree of automation, with processes from material loading, positioning, and unloading to the ejection of defective products all being completed automatically without the need for manual intervention. This not only saves labor but also enhances production efficiency and consistency.
D. Gearbox Assembly Section
1. Automated Material Supply: The use of a vibration feeder ensures the continuity and stability of the material supply.
2. Automatic Assembly and Welding: After manual loading of the gearbox cover, it is automatically assembled into the gearbox and welded using hot-melt welding technology to ensure the consistency and sealing of the welds.
3. Precision Inspection: Multiple inspection devices are in place to ensure the precision of production. For instance, the cup washer missing detection sensors and CCD visual inspections for missing grease, ensuring the accuracy of each production step.
4. Box Assembly and Shock Protection: Motors that pass inspection are packed in boxes, and shock-absorbing pads are attached at designated positions to protect the motors during transportation.
5. Label Engraving and Tracking: TIG lasers are used to engrave labels at designated positions on the motors. This step not only improves product traceability but also, through barcode scanning, further improves the efficiency of production management. Any defective products are automatically ejected, ensuring high-quality and efficient production.
HONEST Automation values the quality and efficiency of every production link. Our sunroof motor assembly line ensures the production quality of the products through precise process flows and intelligent equipment. We are committed to continuously improving through technological innovation and research and development, providing customers with more efficient and high-quality production equipment.
Reasons to Choose HONEST Automation as Your Motor Production Equipment Supplier:
1. Extensive Experience and High Manufacturing Standards: Since its establishment in 2007, HONEST Automation has been dedicated to the research and development and production of motor production equipment, serving numerous domestic and international enterprises and accumulating rich industry experience. We have also received multiple “Best Delivery Awards” from our customers, which is an affirmation of our professional technology and services.
2. Comprehensive Service System: We provide dedicated service throughout the pre-sale, sale, and after-sale process, ensuring that your needs and inquiries are responded to promptly and effectively.
3. Customized Solutions: We offer customized semi-automatic or fully automatic equipment solutions based on your product process flow and production requirements to meet your specific production needs.
4. Prototyping Services: We provide prototyping services to ensure that the equipment solutions we offer perfectly fit your actual production needs.
5. High Flexibility of Equipment: Our equipment design takes into account the variability of production needs, allowing for quick model changes with only minor structural adjustments to meet different production tasks.
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If you wish to learn more about the process flow or individual equipment of our sunroof motor assembly line, please feel free to contact us at any time. Our professional team is looking forward to receiving your message.
