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Robotically Loaded Rotor and Magnet Bonding Automation

The Challenge: Design a fully automated multi-station rotor assembly machine. The machine must automatically:

• Accept machined rotor shells (multiple types and sizes)
• Automatically load magnets (multiple types and sizes)
• Apply two part epoxy to shell and magnets using positive displacement dispensing system
• Provide magnet bonding with individual bonding force feedback and control
• Part cure storage and process control
• Individual part inspection

Parts must then be placed on a transfer station to be shear tested and magnetized.

Solution:

The following methods, components and technologies were implemented and integrated to provide a comprehensive solution:

• Dual manually loaded magnet part slides
• Robotic part handling (magnets and rotor shells)
• Automatically loaded magnet holding tooling
• Automatic positive displacement glue dispensing on each magnet
• Individual part servo controlled bonding axis'
• Individual part force feedback bonding axis'
• Robotically controlled cure rack
• Part Inspection using laser line generator and Cognex Vision System

Impact to the Customer:

• Part rate of 1 part assembled every <50 seconds
• Parts are automatically assembled
• All magnet pressing is verified using individual axis load cell feedback
• All parts are 100% inspected and verified
• Bad parts are automatically identified

 

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