How do motor manufacturers customize a suitable motor assembly line?

The core of the motor manufacturer's custom-made motor assembly line is around the three core elements of "own product characteristics", "capacity demand" and "degree of automation", and through the process of "clear demand → scheme design → landing verification", the assembly line is ensured to adapt to production, giving consideration to efficiency and cost.

First, the early stage: define the core requirements and lay the foundation for customization.

Product parameters and process carding

Clarify the motor type and specification: it is necessary to determine the category (such as servo motor, stepping motor and asynchronous motor), size range (such as external diameter of 50-200mm) and core assembly process (such as stator winding → rotor press-fitting → bearing assembly → end cover installation → performance test) of the production motor, and sort out the precision requirements of each process (such as bearing press-fitting coaxiality ≤0.02mm) to avoid the assembly line and products from being inconsistent.

Statistics of production process details: record the operation standards of key processes (such as press-fitting pressure and tightening torque), material forms (such as whether the bearing is equipped with dust cover and whether the end cover is pre-assembled with sealing ring), and special requirements (such as anti-static assembly of explosion-proof motor and dust-free environment of micro motor).

Production capacity and automation demand positioning

Determine the production capacity target: define the demand according to the "daily production capacity/shift capacity" (for example, the daily production capacity is 500 units, with two shifts), and push back the takt time of the assembly line (for example, the beat is ≤1.5 minutes/shift) to avoid overcapacity or shortage.

Selection automation degree: it is recommended to "semi-automatic+manual assistance" for small batch and multiple varieties (such as changing models ≥5 times per month) (such as manual feeding and automatic press-fitting); A large number of single varieties (such as annual output of ≥ 100,000 sets) can choose full automation (such as mechanical hand feeding, automatic detection and AGV transfer) to balance efficiency and flexibility of type change.

Second, the mid-term: project design and supplier cooperation, control the core link.

Customization and adaptation of core module

Process flow planning: design moving lines according to the principle of "smooth logistics and reduced turn-back", such as "feeding → stator treatment → rotor assembly → final assembly → testing → off-line" to avoid cross-line handling; Power-assisted mechanical arm is set for heavy manual work procedures (such as motor assembly turnover) to reduce labor intensity.

Selection of key equipment: Select equipment according to process accuracy, such as "servo press" for bearing press-fitting (pressure accuracy 1%) and "automatic tightening machine" for screw tightening (torque accuracy 3%); A "comprehensive performance tester" (which can measure speed, torque and insulation resistance) is required in the testing process to ensure the factory quality.

Collaborative optimization with suppliers

Provide detailed technical input: provide the supplier with 3D drawings, BOM list and process documents of the motor, and specify the equipment interface requirements of each process (for example, the height of the material conveyor belt is 850mm±50mm, which is suitable for manual operation).

Scheme review and simulation: Require suppliers to produce 3D layout of assembly line, and review logistics path, equipment spacing and reserved space (such as reserving 1-2 stations for later capacity expansion); For complex processes (such as interference fit assembly of stator and casing), small prototype test can be required to verify the feasibility of the process.

Third, the later stage: installation, debugging and acceptance to ensure the landing effect.

Installation and debugging in stages

Step-by-step installation: first install basic equipment (such as conveyor belt and fixture), then install electrical system (such as control cabinet and sensor), and finally connect automation modules (such as robotic arm and AGV) to avoid damage caused by cross construction.

Hierarchical debugging: first single-machine debugging (such as testing the pressure of the press and the torque of the tightening machine), then online debugging (such as testing whether the material flow between processes is smooth), and finally debugging with materials (trial production with 100-200 parts to optimize the beat and accuracy).

Strict acceptance and personnel training

Formulate acceptance criteria: acceptance from three aspects: "capacity, accuracy and stability", such as capacity reaching rate ≥95%, accuracy of key processes meeting process requirements, and trouble-free continuous operation for 8 hours; 10% of the motors shall be sampled in the test, and the performance qualification rate shall be 100%.

Conduct operation and maintenance training: the supplier is required to train operators in equipment operation (such as parameter setting and fault alarm handling), and train maintenance personnel in daily maintenance (such as equipment lubrication and sensor calibration), and provide Operation Manual and Maintenance Manual.