Midwest Engineered Systems

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Waukesha, WI

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Rotor Assembly Machine

Project summary:

Designed and built a Robotic Rotor Assembly System. Customer’s cycle time decreased to one assembled rotor every 50 seconds.

The Challenge

A firm came to Midwest Engineered Systems looking to design a fully automated multi-station rotor assembly system. This system must automatically:

  • Accept machined rotor shells of multiple types and sizes
  • Automatically load magnets with multiple types and sizes
  • Apply two-part epoxy to the rotor shell and magnets using a positive displacement dispensing system
  • Provide magnet bonding with individual bonding force feedback and control
  • Part cure storage rack
  • Individual part inspection
  • Parts must then be placed on a transfer station to be shear tested and magnetized

The Solution

MWES designed and built a robotically Loaded Custom Automated System. The customer’s cycle time decreased to one assembled part every 50 seconds. 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 tended cure rack
  • Part Inspection using laser line generator and Cognex Vision System

Impact to the Customer

The automation system that MWES provided this customer brought about the following improvements:

  • Part rate of one part assembled every 50 seconds or less
  • 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


Midwest Engineered Systems has a wide range of experience in building custom automation systems. If you’re looking to improve your automation throughput, we have the knowledge and experience to make the project a success.

Contact us to learn about how Midwest Engineered Systems can automate even your most complex and challenging operations today!

Client Details

Manufacturer of large industrial power transformers​

Services Provided

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