Case Study: Water Heater Blower Motor Assembly Line Delivered to a Korean Automotive Motor Manufacturer
Customer Profile
The customer is a globally recognized automotive motor manufacturer specializing in the R&D and mass production of automotive DC motors. Its products are widely used in automotive applications such as blower motors, EPS motors, and brake system motors. With strong R&D capabilities, consistent manufacturing quality, and a global service network, the company has earned recognition and trust from leading automotive customers worldwide.
To support its global growth, the company has established R&D centers, technology centers, and manufacturing facilities in key regions, including the United States, China, and India. Through its integrated global operation network, the company continues to drive innovation in automotive motor technologies and advance intelligent manufacturing capabilities.
Project Background & Challenges
With growing market demand for its blower motors, the customer's existing production capacity could no longer keep pace with increasing production requirements. To support business expansion, the customer sought to enhance manufacturing efficiency, increase production capacity, and achieve a higher level of automation in its motor production processes.
Key challenges included:
The stator is internally wound with fine copper wire. After winding, the terminals are cut by a clockwise rotating turntable, and the insulation layer at the wire ends is pierced before terminal pressing. Due to the delicate nature of the wire, precise control of the winding tension and wire connection process is critical. Any improper tension adjustment during winding may lead to copper wire breakage, causing product defects and affecting overall production yield.
Solution Provided by Honest Automation
Honest Automation delivered a water heater blower motor assembly line.
The production line supports the production of two different motor winding configurations with the same stator core. To ensure stable and reliable manufacturing performance, the line is equipped with an electronic wire tension monitoring system, copper wire protection mechanism, counterweight module, and independent wire racks. In addition, the electrical cabinet features built-in cooling fans to improve heat dissipation and ensure continuous operation, fully meeting the customer's production requirements.
Main Equipment Advantages:
The stator assembly line achieves a cycle time of ≤28 seconds, while the rotor assembly line reaches ≤14 seconds. With optimized process allocation and efficient production flow, the system delivers high output within a limited production time.
The production line supports rapid switching between two winding specifications (220V and 110V) using the same stator core, enabling flexible mixed-model production for multiple orders.
The electronic wire tension control system monitors winding tension in real time, ensuring consistent winding quality and preventing copper wire damage during the production process.
The bottom-mounted counterweight module effectively reduces vibration, while the welded square tube frame and optimized heat dissipation design ensure long-term stable operation and equipment reliability.
Equipment Parameters:
Stator line CT ≤ 28s, Capacity: ≥ 126 PCS/hour;
Rotor & Assembly Line CT ≤ 14s, Capacity: ≥ 252 PCS/hour
Yield Rate: ≥ 98%
Availability: ≥ 90% for the entire line
Required Personnel: Approximately 2-3 operators
Why Choose HONEST Automation
Extensive BLDC Motor Winding Expertise and Proven Experience
HONEST Automation has extensive experience and proven success in BLDC motor winding applications. With deep technical expertise in motor manufacturing processes, the company can effectively address challenges encountered during blower motor winding and provide reliable, stable, and efficient automated motor production solutions.
Localized Sales and After-Sales Support in Korea
With a local sales and service team in Korea, HONEST Automation provides fast response, professional technical support, and localized after-sales services to ensure smooth project implementation and stable equipment operation.
Long-Term Partnership and Competitive Solutions
HONEST Automation is committed to building long-term partnerships with customers by delivering reliable, cost-effective, and customized automation solutions that meet different production requirements.
Strong R&D Capabilities and Experience with Leading Companies
Through cooperation with leading companies in Korea and global markets, HONEST Automation has developed strong R&D capabilities and engineering expertise, continuously driving innovation in motor manufacturing technologies and providing advanced intelligent manufacturing solutions.
