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(click image for full size) |
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| Capable of producing one stator every 15-20 seconds (2 pole, 4 pole, multi-speed or three-phase), this system can produce two different motor laminations simultaneously in a flex-flow production press. |
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(click image for full size) |
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Key Change-Over Features Include:
- Stack height change-over of the entire system within 5 minutes.
- Fully automated pole configuration change-overs
- Fully automated lamination change-overs
- Capable of integration with the Alliance patent pending automatic wire change-over system for automatic wire change-overs WITHOUT AN OPERATOR!
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The Key Stations on the Line are:
- Automatic accumulation to the slot cell insulator for interlocked laminations with automatic transfer to the linear injection tooling pallet system.
- Stator welding, insulator and automatic transfer for a second lamination to the same linear injection tooling pallet system.
- Six shed winders winding directly into the upper injection tooling.
- Two dual-servo axis wedgemakers for high speed reliability.
- Two four-servo axis coil injection stations with controlled and timed motions to reduce coil injection force that optimizes stator slot fills and greatly improves motor efficiency.
- Two pre-form/final form presses: This unique design both pre-forms and final forms the stator coil ends turn within the same tooling station. This provides the best method to encapsulate and compress the end turns for the smallest possible motor size within a power rating.
- Two automatic test/bond and form press stations test the stator for electrical performance, then transfer the stator to a resistance heating station where heat-initiated epoxy bonds the wire securing the motor with a higher strength material, while reducing the hazards associated with normal liquid resin application.
- Ink jet printing on the stator after test with a number that can trace the stator back through the system, maintaining a historical record.
- Two stator shell presses with automatic unload to final assembly conveyor. These stations protect the pre-coated motor housing and set up quickly for any customer mounting requirement.
- Two pallet conveyor lines with radio frequency tag readers.
- Manual processes are minimized. The manual Lead Placement Station provides operators with photographic guides for lead positioning, combined with downstream automatic termination to reduce the time it takes to locate any lead combination.
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| The assembly line is controlled by a server running Windows-based software, with an ethernet interface providing a standard TCP/IP link to factory and IT networks. This system includes 78 servo motors for automatic set-up of all machines in the system and repeatability for demand flow production scheduling. This state-of-the-art motion control system utilizes the latest in PCI-based motion control cards which provide for the greatest degree of control and flexibility. |
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| Given the extremely wide range of motor specifications produced by the motor manufacturer, production runs of a custom motor design may be separated by several months. Closed-loop motion control technology provides the speed and the positioning accuracy to return all station parameters back to processes developed months earlier - eliminating the constant re-adjustment commonly required by other automation systems. |
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Copyright © by Alliance Winding Equipment, Inc., Joyal, & AWE-Newtech. All Rights Reserved. Federal copyright law prohibits unauthorized reproduction of web content by any means and imposes fines for any violation. |
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