In the assembly process of brushless motor rotors, the choice of technical route is crucial. It is not only related to production efficiency, but also directly affects the quality and cost of products. Vacuz will deeply explore the application of automated assembly lines and modular design in brushless motor rotor assembly, as well as how to achieve efficient production and quality improvement through quality control of key processes.

1. Selection and recommendation of core assembly methods

1. Fully automated assembly line: a common choice for high-end manufacturing

For large enterprises with an annual output of more than 500,000 units, fully automated assembly lines are undoubtedly the best choice. It is not only compatible with rotors of various specifications, but also achieves a high degree of automation and accurate control in key processes such as magnetic steel assembly, bearing press fitting and dynamic balancing correction. Through the integrated application of servo press fitting equipment, constant force press and fully automatic dynamic balancing machine, the fully automated assembly line not only greatly improves production efficiency, but also ensures product consistency and high quality.

2. Semi-automation + modular design: a flexible and efficient transition solution

For enterprises with an annual output of 100,000 to 500,000 units, the combination of semi-automation and modular design provides a more flexible and efficient transition solution. It can quickly switch product specifications while ensuring a certain production efficiency to meet the changing needs of the market. Through the application of pneumatic clamps, modular positioning pins and AI visual inspection modules, the semi-automatic assembly line has performed well in terms of changeover speed and product defect rate control.

2. Key points of quality control of key processes

1. Magnetic steel assembly: dual guarantee of precision and strength

Magnetic steel assembly is one of the key processes in the assembly of brushless motor rotors. In order to ensure full contact and firm bonding between the magnetic steel and the iron core, it is necessary to process high-precision magnetic steel positioning grooves on the rotor iron core and strictly control the thickness of the glue layer. At the same time, for multi-pole magnetic steel, a servo motor-driven rotating table is also required to ensure accurate alignment of the magnetic poles and avoid excessive motor vibration.

2. Bearing press-fitting: dual control of cleanliness and press-fitting force

The quality of bearing press-fitting directly affects the operating performance and life of the motor. Therefore, before press-fitting, the bearings and rotor journals need to be strictly cleaned to ensure that the cleanliness meets the standards. At the same time, through real-time monitoring and analysis of the pressure-displacement curve, it can be ensured that the press-fitting force meets the process requirements and avoid problems such as bearing damage or poor assembly.

3. Dynamic balancing correction: accurate deweighting and correction surface selection

Dynamic balancing correction is of great significance to improving the running stability and reducing noise of the motor. Through accurate deweighting methods such as laser deweighting or milling deweighting, the balancing accuracy of the rotor can be ensured to meet the standard. At the same time, the reasonable selection of the correction surface according to the rotor structure can further optimize the balancing effect.

In summary, the efficient automation solution and quality improvement strategy for brushless motor rotor assembly is a systematic project, which requires comprehensive consideration and implementation from multiple aspects such as technical route selection, key process quality control and production efficiency improvement. Through continuous optimization and innovation, we can create greater value for enterprises and promote the high-quality development of the manufacturing industry.

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