High Voltage eMotor Assembly Lines

General Information

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FAL Motor Assembly and Testing Line (1) | 2020

The FAL Motor Assembly and Testing Line (1) is a fully integrated production system for assembling and testing electric motors. Designed for high-volume automotive production, the line combines automated, semi-automated, and manual operations within a continuous material flow concept. With a cycle time of approximately 86 seconds per unit, an OEE of around 85%, and a footprint of about 855 m², the system ensures efficient and stable production performance. The line consists of 25 stations covering the entire process chain from initial component loading to final packaging. The process begins with robotic loading and thermal shrinking of stator and housing components, followed by cooling and manual sealing operations. Core assembly includes housing joining, rotor magnetization, and A-shield integration. Subsequent steps involve mechanical assembly operations such as screwing and interconnector installation. The line integrates comprehensive end-of-line testing, including electrical tests, leak tests, rotation checks, and marking processes. Final stages include assembly of protective components, packaging, and reintegration handling. This line represents a complete, high-throughput solution for automotive eMotor assembly with integrated quality assurance.

Stator Assembly Line (1) | 2020

The Rotor Assembly Line (1) is a fully automated production system for manufacturing and balancing rotor assemblies. It is designed for high-volume, precision-driven automotive production. Operating at a cycle time of approximately 86 seconds per unit with an OEE of around 85% and a footprint of about 509 m², the line ensures consistent output and process stability. The system comprises 11 stations covering the entire rotor assembly workflow. The process starts with semi-automatic loading of rotor components, including shaft insertion and thermal processing. This is followed by rotor pressing and laser marking. Subsequent stages involve automated resin application and magnet assembly for both large and small magnets. After curing, the process includes preparation and cleaning steps to ensure quality consistency. Inspection stations verify resin levels and magnet positioning. The final stages focus on dynamic balancing, including pre-balancing, spinning, and final balancing operations. The line integrates automated handling, inspection, and balancing technologies, ensuring high precision and repeatability for rotor production.

Rotor Assembly Line (1) | 2020

The Stator Assembly Line (1) is a comprehensive production system for manufacturing stator units. The line is designed for high-volume automotive production and integrates automated and manual processes. With a cycle time of approximately 86 seconds, an OEE of around 75%, and a total area of about 1,500 m², the system supports efficient stator production. The line includes 17 stations covering all stages from subassembly to final impregnation. Initial steps include end plate assembly and stator stack preparation. Core processes involve insertion of slot insulation, multi-station winding, and manual insulation assembly. Wire pre-forming and separator installation follow as intermediate steps. Further operations include connector crimping, forming, and lancing processes. The stator stack is then skewed and laser welded. Final stages include electrical testing, heat shrink assembly, and resin impregnation. The line ensures reliable production quality through controlled forming, joining, and testing processes, making it suitable for demanding automotive applications.

FAL Motor Assembly and Testing Line (2) | 2021

The FAL Motor Assembly Line (2) is a fully automated system for assembling and testing electric motors. The line follows a structured layout supplied by PIA Automation and is designed for high-volume automotive production. With a cycle time of approximately 86 seconds, an OEE of around 85%, and a footprint of about 760 m², the system provides efficient and compact production capabilities. The line consists of 25 stations covering the complete assembly process. The process begins with automated loading, thermal shrinking, and cooling of components, followed by manual sealing and housing preparation. Core assembly operations include rotor magnetization, housing joining, and A-shield integration. Mechanical assembly steps such as screwing and interconnector installation are followed by integrated testing processes. End-of-line operations include electrical testing, leak testing, functional verification, and marking. Final operations cover component finishing, packaging, and reintegration. The line offers a compact yet fully capable solution for high-quality eMotor assembly.

Stator Assembly Line (2) | 2021

The Rotor Assembly Line (2) is a fully automated production system for rotor assembly and balancing. It is designed for high-volume automotive production with consistent quality output. The line operates at approximately 86 seconds per unit, with an OEE of around 85% and a footprint of about 509 m². It consists of 11 stations covering the complete rotor manufacturing process. Initial operations include semi-automatic loading, shaft insertion, and thermal processing. This is followed by rotor pressing and laser marking. Automated stations perform resin application and magnet assembly for different magnet sizes. Curing, preparation, and cleaning steps ensure process stability before inspection. Quality control stations verify resin levels and magnet positioning. Final stages include balancing, spinning, and final balancing processes. The system integrates automated handling and precision balancing technologies, ensuring high repeatability and efficiency in rotor production.

Rotor Assembly Line (2) | 2021

The Stator Assembly Line 2 is a fully integrated production system for stator manufacturing. It is designed for high-volume automotive applications and combines automated and manual processes. The line operates with a cycle time of approximately 86 seconds, an OEE of around 75%, and occupies about 1,500 m². It includes 17 stations covering the entire stator production workflow. The process begins with subassembly and stator stack preparation, followed by insertion of slot insulation and multi-stage winding operations. Manual and automated steps ensure proper insulation and wire forming. Intermediate stages include separator assembly, connector crimping, and final wire forming. Subsequent processes include lancing, cutting, and laser welding of the stator stack. Final operations involve electrical testing, installation of heat shrink components, and resin impregnation. The line ensures high-quality stator production through controlled and repeatable processes suitable for automotive manufacturing.