EV Car Motor Assembly and Testing Line

PIA Automation Assembly and Testing Line

EV Car Motor Assembly and Testing Line (2021)

Designed to produce EV motors in the power range of 180–300 kW
Including manual, semi-automated, and automated operations
Cycle time: 86s

Stations and Equipment

Component loading
- KUKA KR15 R2700-2/FLR robot (2021)
- Material infeed
- Inner housing heating with induction coil up to 240 °C
- Stator pressing into housing
- 1T TOX press
- Keyence CA-DQP25X
- Cooling tunnel
- Cooldown to 24 °C
- Cycle time: 600 s

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X-ring and D-ring inner housing assembly
- X-ring and D-ring seal insertion into housing
- Dedicated round assembly tool available

Outer housing pre-assembly
- Flange screw into housing with Bosch Rexroth ESA013G-G0 screwdriver
- Automatic inner and outer housing joining

Outer housing assembly
- 3T TOX EQK 030 press
- 2x Cognex scanners
- 2x Keyence Camera V3
- 3x VS camera systems

Rotor magnetization and measurement
- Magnet magnetization
- MagSys magnetizer MC3K82 (2020)
- Magnetizing fixture MFFer8/160/250

A-shield pre-assembly and rotor insertion
- Rotor bearing and resolver pressing
- 3T TOX press

A-shield assembly into outer housing
- 1T TOX EQK press
- A-shield screwing into outer housing with pneumatic screwdriver (5 Nm)

Mounted component fastening
- Fastening with 4GE59 Rexroth screwdriver
- Manipulator system Handyflex 400

Inter-connector connection
- Manual mounting of inter-connector and insulating tube

Counter ring insertion, cooling cover, and vent assembly
- 3T TOX EQK 030 press

Rotor cooling cover mounting
- Screwing with 4 Nm

End-of-line (EOL) electrical testing loop
- 5x Deutronic testers, including:
- ETL ATS 400 high-voltage testers
- HIOKI RM3545 resistance testers
- Reilhofer EOL analyzers

Inter-connector disconnection station
- Disconnection of the inter-connector
- Insertion of 2 screws and screwing with Rexroth screwdriver (13 Nm)
- Manipulator system Handyflex 300
- Washer control
- Motor rotation

Leak testing
- 2x Leak test stations with Innomatec LTC-902 testers
- Vacuum and overpressure leak tests
- Tested quantity: approx. 50,000 pcs per test station

Rotation, laser marking, stamping, engraving, and inspection
- ADT stamping machine
- Arex Laser 450
- Keyence CA-H camera system
- Datalogic CBX 100 reader
- Tested quantity: approx. 130,000 pcs

Transportation protection
- Yellow transportation cover/cap and plug assembly
- Manual insertion of caps and hole securing

Packaging and final inspection
- Dalmec manipulator (2022)