EV Car Rotor Assembly Line (2021)

EV Car Rotor Assembly Line (2021)
Designed to produce rotors in the height range 300–460 mm
Including manual, semi‑automated, and automated operations
Cycle time: 86 s
Manufacturer: TeamTechnic (Nextomation)

Stations and Equipment

Rotor package and shaft loading, shrinking, and cooling
KUKA KR120 R3900‑2K/FLR robot (2021) with camera system
3x semi‑automated material infeed for rotors (high and low versions)
3x semi‑automated material infeed for metal sheet packages
Automated sheet‑metal package heating and shaft insertion
Rotary table with 6 heating stations, up to 300 °C

Rotor pressing, locking, and laser marking
Automated pressing with 10 T Kistler press and package locking using a Bosch 4GE 59 screwdriver (90 Nm)
Laser marking with Arex 420 laser

Resin application and large magnet assembly
Manual magnet belt feeding on trays
Automated large magnet insertion and sealing
Scheugenpflug LiquiPrep LP 804 resin dispensing unit

Resin application and small magnet assembly
Manual magnet belt feeding on trays
Automated small magnet insertion and sealing
Scheugenpflug LiquiPrep LP 804 resin dispensing unit

Resin gelling and curing
Automated operation for 150 pcs at 200 °C

WPC tooling preparation station
Press plate cleaning station

Package unlocking, resin level, and magnet position control
Automated assembly tool removal with a Bosch 5DMC530 screwdriver (90 Nm)
Resin level and magnet position control

Balancing
Automated balancing with pin insertion and verification
KUKA KR120 R3100‑2/FLR robot (2021)
2x Schenk eTeno balancing machines (2021)
2x 1.5 T Kistler presses

Spinning
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Automated aging and working‑condition simulation up to 120 °C
KUKA KR120 R3100‑2/FLR robot (2021)
3x Hoffmann ESV25‑AR2 spinning stations (2022)
4x cooling tracks

Final balancing
Automated balancing with pin insertion and verification
KUKA KR120 R3100‑2/FLR robot (2021)
2x Schenk eTeno balancing machines (2021)
2x 1.5 T Kistler presses