New Energy Vehicle Motor Automated Production Line Product Overview

JiuJu Automation new energy vehicle motor automation production line is an integrated intelligent manufacturing solution for the large-scale and high-precision assembly of new energy vehicle drive motors (including pure electric, hybrid, electric bus and other models). The production line deeply fits the core process requirements of the whole process of motor stator, rotor and machine assembly, integrates high-precision robot system, modularized conveying equipment, intelligent testing unit and MES production management system, realizes the unmanned operation of the whole process from parts loading, core process assembly to finished product testing and discharging, which can effectively solve the industry pain points of low efficiency, poor precision, lack of consistency and high labor cost in the traditional production mode. It can effectively solve the industry pain points of low efficiency, poor precision, lack of consistency and high labor cost in the traditional production mode, and provide stable, efficient and flexible mass production support for automobile enterprises and motor manufacturing enterprises.

The production line takes the core assembly process of motor as the core, and builds three core sections, namely stator assembly, rotor assembly, and complete machine assembly, which are seamlessly connected to each section, comprehensively covering the key processes in the whole chain of motor production, and with strong process adaptability, it is compatible with the production requirements of various flat-wire motors and traditional round-wire motors such as Hair-pin, X-pin, Mini-pin, etc., and supports the production of motors of different power and different models. Flexible switching production.

I. Automation of core work sections and key processes

(i) Stator assembly section: high-precision core process integration operation

As the core component of motor power output, the stator assembly precision directly determines the motor power density and operational reliability. This section realizes fully automated closed-loop operation from insulation treatment to coil molding and welding inspection, and the key process highlights are as follows:

• Intelligent loading and insulation assembly: Equipped with special loading mechanism and high-precision manipulator, it realizes automatic loading and positioning of stator core, automatic folding, cutting and inserting of insulating paper, adapting to a variety of groove structures, and double edge chamfering design to avoid interference with coils, and the precision of insulating paper assembly reaches ±0.05mm, which guarantees the reliability of insulation.
• Coil forming and embedding: integrating universal wire making machine and coil embedding equipment, supporting 2D+3D integrated forming of multi-strand flat/round wire, completing the production of a single set of wires within 5 seconds, and the time for changing the shape is ≤80 minutes; precisely controlling the winding speed, mold lifting and positioning of wires through servo, realizing efficient embedding of coils, and adapting to the needs of 6-wire and 12-layer or less stator windings, with the deviation of the wire-end height being controlled within 0.3mm.
• Twisting, Welding and Paint Curing: Adopting self-developed flat-free twisting technology, the twisted wire is flat without additional cutting process, the production cycle of a single piece is ≤90 seconds, which effectively saves materials and avoids quality hazards; Equipped with high-precision laser welding/resistance welding equipments, it realizes the automatic welding of the coil ends and busbar rows, with uniform and stable welding strength; Equipped with vacuum paint dripping mechanism, the paint dripping head can be adjusted at any angle from 0-90 degrees, and the filling rate reaches more than 95% with high-frequency heating system. The filling rate reaches more than 95%, with high-frequency heating system, the paint can be cured quickly to improve the insulation performance and temperature resistance of the stator.
• Online inspection: Integrated 2D/3D visual inspection and electrical performance testing unit, real-time inspection of coil molding accuracy, welding quality, insulation performance, and automatic rejection and alarm of non-conforming products to ensure the consistency of each stator product.

(II) Rotor assembly section: efficient stabilization and precise control of dynamic balance

Rotor assembly focuses on core processes such as magnet assembly and axial press fitting, taking into account production efficiency and dynamic balance accuracy, the key processes are realized as follows:

• Tile/magnet steel automatic assembly: through the multi-bin tilting loading, tile automatic separation and positioning mechanism, realize the precise embedding of tile into the rotor core, with the automatic glue spraying system, to ensure the reliability of tile fixing and avoid the risk of falling off during operation.
• Shaft pressing and processing: Liquid nitrogen cooling and heating process is adopted to realize the interference fit pressing of the rotor shaft and iron core, with real-time monitoring of the pressing force and displacement, and the precision of pressing reaches ±0.01mm; the subsequent simultaneous completion of the assembly of dynamic balancing plate, locking riveting and demagnetization of the shaft head ensures the dynamic balancing performance of the rotor, and reduces the noise and vibration of the motor operation.
• Full-process traceability: Real-time data collection for each process, including magnet type, press-fit parameters, balancing accuracy, etc., supports full life-cycle traceability of the product, and cooperates with magnetization and laser marking processes to realize unique management of rotor identity information.

(iii) Complete machine assembly section: seamless integration and final inspection of finished product performance

This section realizes the precise fitting of stator, rotor, shell, connector, resolver and other parts, as well as the final performance testing of the finished motor to ensure that the ex-factory products comply with the operating standards of the whole vehicle:

• Cooperative assembly of multiple parts: through the modularized conveying line and multi-axis manipulator, it can realize the automatic positioning and assembling of stator, rotor and shell, equipped with error-proof mechanism and locking device to ensure that the parts are assembled in place and the assembling process is smooth and damage-free.
• Accessory assembly and integration: automatically complete the assembly and fixation of connectors, resolver, end caps and other accessories, wires are organized in an orderly manner to avoid interference, ensuring the stability of the overall structure of the motor and the reliability of signal transmission.
• Comprehensive inspection of finished products: Integrating multi-dimensional inspection units such as airtightness inspection, electrical performance test, no-load running test, real-time inspection of motor insulation resistance, winding resistance, speed, torque, noise and other key indicators, inspection data is automatically uploaded to the MES system, qualified products are automatically discharged into the warehouse, and non-qualified products are automatically shunted to be processed.

Second, the core advantages: precision, efficiency, flexibility, intelligence

• Ultra-high precision, quality control: the whole process is controlled by servo motors and high-precision manipulators, with a repeatable positioning accuracy of ±0.05mm, and the accuracy of key processes can be as high as ±0.01mm. With multi-dimensional online inspection, the product qualification rate has been increased to over 99.5%, which guarantees the stability and consistency of the motor's operation.
• High-efficiency mass production, cost reduction and efficiency: stator assembly beat can be up to 60 seconds / piece, rotor assembly beat 128 seconds / piece, the overall efficiency of the entire production line compared with the traditional manual production line to enhance 3-5 times, significantly reduce labor input, reduce the risk of manual errors, and effectively control production costs.
• Flexible adaptation, quick changeover: The modular design concept runs through the entire production line, equipped with 36 kinds of line mold bins and quick changeover mechanism, supporting the quick switchover of motors of different models and processes, with a short changeover time to meet the needs of automobile enterprises for mass production of multiple platforms and models, and avoiding the waste of production capacity.
• Intelligent interconnection, full traceability: Equipped with MES production management system, it realizes real-time collection, analysis, uploading and distribution of production data, covering the full dimensions of data such as equipment operation status, production progress, product quality, material information, etc., supports remote monitoring, fault diagnosis and production scheduling, builds a full-process digital traceability system, and assists the enterprise to realize the upgrade of intelligent manufacturing.
• Safe and stable, low consumption and environmental protection: the production line is equipped with perfect safety protection system and fault diagnosis mechanism, the noise of the equipment operation is <75db, which is in line with the environmental protection standard of industrial production; the key components adopt high-precision machining process, and the implementation of the life-cycle management, the equipment failure rate is low, and the maintenance cost is low, so as to ensure that the production line operates continuously and stably for 24 hours.

III. Application Value and Scenarios

JiuJu automation new energy vehicle motor automation production line, widely used in new energy vehicle enterprises, motor assembly manufacturing enterprises, core parts and components supporting enterprises and other scenarios, can be customized according to the customer's production capacity needs (from the annual output of 100,000 sets to 1 million sets) production line configuration, to provide from the program design, equipment development, installation and commissioning to the after-sales operation and maintenance of the integrated services. Through the application of the production line, the enterprise can realize the intelligentization and upgrading of motor production, significantly improve product competitiveness, and help the new energy automobile industry to develop in the direction of high efficiency, energy saving and high quality.

In the future, JiuJu Automation will continue to focus on the new energy automobile motor manufacturing technology iteration needs, constantly optimize the production line process precision and flexibility level, incorporating more AI intelligent algorithms and digital twin technology, to provide customers with more core competitiveness of the intelligent manufacturing solutions, and build a new ecosystem for the development of new energy automobile industry.