1.Project background

Fawer is a domestic professional manufacturer of automotive micromotors, and wiper motors are its core products. As OEMs continue to increase their requirements for motor noise, lifespan, and performance, the original semi-manual production lines have poor assembly consistency, low testing efficiency, and insufficient dynamic balancing accuracy. Both product quality and production capacity cannot meet the needs of high-end customers, and there is an urgent need for production line automation upgrades.

2. Core pain points

1. Core components such as the rotor and end cover are assembled manually, resulting in large coaxiality deviations, high motor operating noise, and poor consistency;

2. Dynamic balance correction relies on manual operation, with low efficiency and unstable accuracy, which is a double bottleneck in production capacity and quality;

3. There are many finished product performance test items, the manual operation is cumbersome, the efficiency is low, and it is easy to miss detection and misjudgment;

4. There is a disconnect between assembly and testing data, quality problems cannot be accurately traced, and process optimization lacks data basis.

3. Overall solution

Based on the process characteristics of wiper motor products, Guangke Industrial has created a fully automatic whole-line solution from rotor assembly to final testing of finished products. Integrating the four core units of precision rotor press-fitting, automatic dynamic balance correction, automatic assembly of the entire machine, and full-performance online testing enables full-process unmanned production, comprehensively improves assembly accuracy and product performance, and ensures product consistency and production efficiency.

4. Solution core configuration

1. Rotor precision assembly unit

The rotating shaft, iron core, and commutator are automatically loaded, and the servo precision press is used. The press force and displacement are monitored throughout the process to ensure the coaxiality and firmness of the rotor assembly.

2. Automatic dynamic balance correction system

Fully automatic dynamic balancing detection and deduplication correction, with high precision and fast speed, automatically compensates for unbalanced amounts, and reduces motor operating noise and vibration from the source.

3. Automatic assembly of the whole machine

The end cover, worm, reduction box, and shell are automatically assembled, the tightening torque is intelligently controllable, and the entire assembly process data is traceable to ensure the reliability of the entire machine assembly.

4. Full-performance online testing system

Integrated no-load/load performance test, noise NVH detection, life sampling test, automatic judgment of test results, automatic interception of unqualified products, comprehensively guaranteeing factory quality.

5. Whole process traceability and visualization

A traceability code is bound to a single motor, and assembly and testing data are retained throughout the process. The supporting production signboard displays output, yield, and defective distribution in real time to assist on-site management.

5. Project implementation results

1. Production efficiency increased by 35%: the entire process is automated, the entire line rhythm is greatly improved, the single-shift production capacity increases by 35%, and the number of manual workstations is reduced by 70%;

2. Product quality has been significantly upgraded: dynamic balancing accuracy and assembly consistency have been greatly improved, the finished product yield has stabilized at 99.4%, and operating noise and vibration have been significantly reduced;

3. Test accuracy 100%: Fully automatic performance testing eliminates manual errors, completely solves the problem of missed detections and misjudgments, and reduces the after-sales failure rate of products by 70%;

4. Digitization of quality management: The whole process data is traceable, process optimization is supported by accurate data, and the efficiency of product iteration and quality upgrade is significantly improved.

6. Customer value and evaluation

After the production line was put into production, the performance and consistency of wiper motor products reached a new level. It successfully entered the supply chain of many joint venture car companies, and its product premium capability and market share increased simultaneously. At the same time, the stable output of the automated production line also provides customers with a mature model for the upgrading and transformation of other motor products.