What is included in a brushless motor automation line?

It includes stator winding, rotor magnet insertion, magnetization, Hall-sensor assembly, final assembly and testing.

Why are Jiuju lines ideal for BLDC motors?

Servo-driven stations, traceable data and ISO9001 processes deliver the precision and repeatability BLDC applications demand.

Brushless motor automated assembly line solutions

Brushless motor automated assembly line solution covers the whole process of stator winding, rotor assembly, stator-rotor assembly and performance testing. For the production needs of general brushless motor, it integrates the core processes of servo tension high-speed winding, automatic paint dipping and drying, and precision press-fitting, etc., and matches with the online turns detection, dynamic balance correction and visual positioning technology, and realizes the dynamic adjustment of work processes and the whole-process data through PLC+RFID system. Traceability.

Brushless motor automated assembly line solution (images 1)

Brushless Motor Assembly Line · Technical Specifications
Item	Specification
Motor types	Brushless DC (BLDC) motors · inner rotor / outer rotor · home appliances, power tools, pumps, model aircraft (frame per workpiece drawing)
Process coverage	Rotor winding → stator rounding → Hall board and driver board assembly → rotor insertion into housing → magnetizing → dynamic balancing → break-in and aging → end-of-line test
Positioning accuracy	Electric cylinder ±0.02 mm · servo handling module ±0.03 mm · full-line repeat ±0.01 mm
Changeover time	20 min (modular changeover, multi-spec mixed-model production)
Defective rate	≤0.3‰
In-line inspection	Inter-turn short circuit · back EMF · Hall phase · vibration and noise · vision for missing or misplaced parts
Control system	PLC + HMI, MES-ready
Power supply	3-phase AC 380V / 50Hz
Air supply	0.5–0.7 MPa
Safety	Safety light curtain · safety door lock · personnel interlock
Stations · cycle time · output · footprint	Quoted per workpiece and cycle time; line OEE can hold above 85%, hourly output up to 600 units

Rows marked g are standard configuration; remaining values are confirmed against the workpiece drawing.

Customization Process

Customized to the specification and target output of the brushless motor; winding, rounding, magnetizing and break-in stations are cycle-time balanced independently. Seven stages, each with defined deliverables and customer sign-off points.

1
Requirement review
& concept design
7–15 days
Technical proposal
2
Technical freeze
& contract
3–7 days
Technical agreement
3
Design & build
in-house commissioning
30–60 days
Drawings · programs
4
FAT
factory acceptance
3–5 days
Acceptance record
5
Site installation
& SAT
5–10 days
SAT report
6
Production validation
3–10 days
Validation report
7
Final acceptance
& handover
2–3 days
Manuals · spares

Total lead time is typically 45–120 calendar days, with build and in-house commissioning accounting for the largest share. Once the design is frozen, changes to core process parameters (size, cycle time, number of stations) cascade into mechanical, electrical and layout changes and may extend the schedule by more than 30% — technical freeze requires written customer confirmation.

Program Advantages

The OEE of the whole line is stable above 85%, and the hourly production capacity can reach 600 units, which improves the efficiency by 3-5 times compared with the manual line, and reduces the labor involvement above 60%, effectively reducing the defective rate of the products; the modularized design supports the quick changeover within 20 minutes, which is compatible with the mixed production of brushless motors of different specifications in many fields, and takes into account the scaled production capacity and the demand for flexible manufacturing.

Brushless motor automated production equipment

Jiuju Automation-Brushless motor automated production line

Core parameters

We are an automated production line manufacturing of motors with design, R&D, production and after-sales capabilities, which can realize flexible intelligent assembly and non-standard customization as required

Product Recommendation

Deep plowing in the motor industry for many years, the products are widely used in the four core areas, according to the process characteristics of different types of motors to provide exclusive motor assembly automated production line solutions.

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Over the years, we have provided 2500+ motor customers at home and abroad with high-quality motor automated assembly line video cases, and have been highly recognized by customers in the motor industry.