The optimization needs of rotor and stator automated assembly production lines need to be analyzed from many aspects. Vacuz starts from the four dimensions of efficiency improvement, precision assurance, flexible production, and intelligent management, and combines new technologies and practical experience to provide detailed optimization solutions. I hope it can help everyone!

1. Efficiency improvement strategy

1. Process reengineering

Parallel design: Split the original independent processes (such as winding, varnishing, and welding) into parallel workstations, and achieve seamless connection between processes by introducing automatic guided vehicles or efficient conveyor belts, significantly reducing the waiting time of workpieces and improving overall production efficiency.

‌Modular layout: Adopting a U-shaped production line layout, this layout can greatly shorten the material handling distance, reduce unnecessary movement of operators, and further improve production line efficiency.

2. Equipment performance optimization

‌High-speed equipment selection: Select a winding machine with a speed of up to 5000rpm or more, and match it with a high-precision servo drive system to ensure that the winding accuracy reaches ±0.01mm, greatly improving production speed and product quality.

‌Multi-station composite equipment‌: Introducing a composite machine that integrates winding, wire embedding, and press-fitting functions to reduce the number of workpiece turnovers between different equipment and effectively shorten the production cycle.

2. Accuracy assurance system

1. Precision positioning technology

‌Visual guidance system‌: Using advanced 3D visual cameras to identify stator slots, high-precision positioning is achieved, and the positioning accuracy can reach ±0.02mm, ensuring the accuracy of subsequent processes such as wire embedding.

‌Torque control technology‌: Apply high-precision torque sensors in the wire embedding link to monitor and control the wire embedding torque in real time to ensure that the torque fluctuation is controlled within 5%, thereby improving the reliability and stability of the product.

2. Closed loop of quality inspection

‌Online inspection system‌: Equipped with high-precision inspection equipment such as inductance testers and insulation resistance testers, 100% process inspection is achieved to promptly discover and correct quality problems in the production process.

‌AI defect recognition‌: Using deep learning algorithms to build an intelligent defect recognition system, automatically identify common defects such as enameled wire breakage and wire embedding dislocation, and improve quality inspection efficiency and accuracy.

III. Flexible production plan

1. Rapid changeover technology

‌Modular fixture‌: Adopt quick-change chuck design to achieve rapid switching of tooling fixtures, shorten the changeover time to within 30 minutes, and improve the flexibility and adaptability of the production line.

‌Parametric programming‌: Directly call the process parameters of different models of products through the human-machine interface, without manually adjusting the equipment settings, further shortening the changeover time.

2. Intelligent warehousing system

‌Three-dimensional material warehouse‌: Configure a large-capacity automated three-dimensional warehouse to support 8 hours of uninterrupted production to ensure the timeliness and stability of material supply.

‌RFID material tracking‌: Implement RFID full-process traceability for key materials, grasp the material status in real time, and improve the transparency and accuracy of material management.

IV. Intelligent management requirements

1. Digital twin technology

‌Virtual debugging‌: Build a digital model of the production line in the manufacturing execution system, perform virtual debugging and process parameter verification, discover and solve potential problems in advance, and reduce the trial and error cost in actual production.

‌Predictive maintenance‌: Monitor the operating status of equipment through vibration sensors and other means, and use big data analysis technology to warn equipment failures 72 hours in advance to ensure stable operation of the production line.

2. Big data analysis platform

‌OEE analysis‌: Real-time collection of equipment shutdown, failure, changeover and other data, use OEE (equipment overall efficiency) analysis method to locate bottleneck processes and propose improvement measures.

‌Quality traceability system‌: Establish product gene map to achieve full traceability from raw materials to finished products, ensuring that product quality is traceable and controllable.

V. Verification and continuous improvement

1. DOE experimental design

Use statistical methods such as orthogonal test method to verify the effect of different process parameter combinations, determine the optimal parameter window, and provide a scientific basis for production line optimization.

2. Continuous improvement mechanism

Establish a PDCA (plan, do, check, act) cycle mechanism, hold quality improvement meetings regularly every month, summarize and analyze problems and improvement measures in production line operation, and promote technology iteration and continuous optimization of production lines.

3. Expected implementation effect

Through the implementation of the above optimization measures, it is expected that the production line efficiency can be improved by more than 40%, the product defect rate can be reduced by 60%, and the changeover time can be shortened by 70%, truly building a “efficient, accurate, flexible and intelligent” modern assembly production line, providing strong support for the transformation and upgrading of enterprises and high-quality development.

E-pasts: sales@vacuz.com