What do you need to know about the design process of motor assembly line?

This problem is crucial, which directly determines the efficiency, quality and cost of the assembly line. The design process of motor assembly line needs to focus on three cores: production demand, quality assurance and efficiency improvement, focusing on six major issues, such as product characteristics, process flow and equipment selection.

1. Define the core characteristics of motor products.

This is the basis of design, and all processes need to be adapted to the product itself.

Type and specification of motor: it is clear whether it is DC motor, AC motor or servo motor, as well as key parameters such as power, size and weight, which directly affect the layout of assembly station and the bearing capacity of equipment.

Structural complexity: Understand the number of core parts of the motor (such as stator, rotor, end cover, bearing, etc.) and the difficulty of assembly, such as whether it needs high-precision centering or sealing treatment.

Production batch and rhythm: determine whether it is continuous production in large batch or multi-variety production in small batch, the former is suitable for automatic production line, and the latter needs to consider the flexible adjustment ability of production line.

2. Plan the core assembly process

It is necessary to sort out the whole process from parts to finished products to ensure logical coherence and no omissions.

Pretreatment: including cleaning, drying and rust prevention of parts, as well as preheating or pre-lubrication of key components (such as bearings).

Core assembly link: Plan key steps such as stator assembly, rotor installation, end cover fastening, bearing press-fitting, wiring and so on in order to avoid overlapping or rework.

Inspection and post-processing: set up quality inspection stations such as air tightness inspection, insulation performance test and no-load trial operation, and finally plan the cleaning, marking and packaging processes of finished products.

3. Select suitable equipment and tools.

Equipment selection needs to balance the degree of automation, accuracy and cost.

Automation equipment: Manipulators (such as loading and unloading manipulators), automatic press machines and automatic tightening machines can be selected for mass production to improve efficiency and consistency.

Special tools: Special tools such as torque wrench (to control the fastening force of bolts), concentricity detector (to ensure the alignment of stator and rotor) and insulation tester are configured according to the motor characteristics.

Auxiliary equipment: equipped with conveyor belt (such as belt line, double speed chain) to realize workpiece circulation, set up material rack (close to the work station to reduce the picking time) and temporary storage area for unqualified products.

4. Optimize the station layout and logistics.

Reasonable layout can reduce waste and improve overall efficiency.

Principle of station layout: follow "U-shaped layout" or "straight line layout". U-shaped layout can reduce the material handling distance, and straight line layout is suitable for long-flow production; The operating range of each station is controlled within 1.5m to avoid action waste.

Logistics route planning: ensure the shortest route of materials (such as spare parts and semi-finished products) from the warehouse to the workstation, and adopt the "first-in, first-out" material supply mode to avoid workstation accumulation.

5. Formulate quality control and error prevention measures.

The motor requires high precision and safety, so it is necessary to set quality assurance nodes in advance.

Key process control: set parameters monitoring (such as torque value and press-fitting force) for processes that affect performance, such as bearing press-fitting and bolt tightening, and automatically give an alarm if it exceeds the range.

Error-proof design: adopt "error-proof tooling" (such as locating pin to limit the installation direction of parts) and "code scanning traceability" (each part is affixed with two-dimensional code to record assembly information) to avoid wrong assembly and missing assembly.

Clear testing standards: Make clear testing indicators, such as insulation resistance ≥50MΩ and no-load current deviation ≤5%, to ensure that each testing station has clear qualification/disqualification judgment basis.

6. Consider personnel and safety factors

Both operation convenience and production safety should be taken into account.

Staffing: Determine the number of workstations according to the degree of automation. The automation line can reduce the number of personnel, but it needs to be equipped with equipment maintainers; The operation intensity should be considered when starting the work manually, so as to avoid repeated actions such as bending over and raising hands.

Safety protection: automatic equipment is equipped with safety grating (to prevent people from entering the dangerous area by mistake), live detection station is equipped with insulating gloves and electric shock protection device, and the edge of the station is equipped with protective fence.