Axial flux motors serve as high-efficiency electric drive core components for new energy vehicles, electric commercial vehicles and lightweight e-drive platforms, featuring compact structure, high power density and superior torque output compared with traditional radial flat wire motors.
HOLS Automation’s customized non-standard axial flux motor automatic assembly line delivers full-turnkey intelligent manufacturing solutions covering stator and rotor automated assembly, busbar fitting, electromagnetic force press-fitting, air gap adjustment, laser welding, flat wire stator dripping coating, dynamic mixing dispensing and multi-layer curing processes. Integrated with helium leak testing stations and full EOL performance testing workflows, the whole line supports complete full-process data traceability and strictly complies with IATF 16949 automotive mass production standards.
This flexible production line resolves core manufacturing pain points including uneven stator coating, inconsistent air gap precision and winding insulation defects, enabling stable mass production of axial flux e-drive assemblies for global new energy Tier 1 manufacturers. It seamlessly matches vacuum pressure plate pump feeding systems and volumetric dispensing valves for thermal conductive adhesive potting, forming a complete closed-loop automated production system for electric drive units.
Full Automatic Assembly Process
1.Automatic Parts Handling & Pre‑processing
The line provides automatic feeding, precise positioning, surface cleaning, and visual inspection of stators, rotors, housings, shafts, bearings, and insulation components. All parts are identified via code scanning to ensure correct material matching and full‑process traceability.
2.Precision Automatic Sub‑assembly
Robotic and servo press systems perform micron‑level assembly of stator cores, insulation structures, winding modules, and rotor magnets. The line supports automatic dispensing, high‑precision press‑fit, controlled tightening, and dynamic alignment to ensure structural stability and performance consistency.
3.Rotor Magnetization & Precision Calibration
Online automatic magnetization ensures stable magnetic field performance. Electrical parameter calibration and dynamic balancing correction are completed automatically to optimize efficiency, reduce vibration, and extend service life.
4.Complete Machine Assembly & Alignment
The fully automatic system integrates stator, rotor, shaft, housing, bearings, and end covers into a complete unit. High‑precision coaxiality and air‑gap adjustment maintain optimal motor efficiency and low noise operation.
5.Comprehensive Online Performance Testing
In‑line functional testing includes insulation resistance, withstand voltage, phase resistance, no‑load performance, temperature rise, NVH, and service life verification. All data is recorded in real time for quality tracking.
6.Finishing, Marking & Sorting
Automatic installation of connectors, shields, and accessories is followed by laser marking, appearance inspection, and intelligent sorting of OK/NG products. The line supports seamless docking with packaging and logistics systems.
