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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

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:
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- 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)