Manufacture high quality direct drive motors

Our direct drive motor solutions cover the full range of producing both stator and rotor components. Facteon has a track record of supplying a range of manufacturing equipment, integration and automation to leading motor manufacturers. Our focus is on product quality, material efficiency and process repeatability to ensure a high quality product for your customers. 

Press & lamination tooling

A high speed and precision press is combined with a fine blanking tool to pierce and separate two lamination strips from a single steel strip. This lamination strip design minimises material waste and enables a precise lamination winding process. 

Lamination winding

Our unique lamination winder technology winds a continuous notched out strip into a helical lamination coil. This coil uses laser welding technology to connect each layer. The dimensional accuracy of this system produces a highly repeatable lamination component. 

High-speed wire winding

Our servo-controlled high-speed winding equipment is designed to dynamically maintain the level of tension required for each unique stator pole shape. Superior winding control is essential in maintaining insulation integrity and product reliability. 

Terminal insertion & testing

The final stator manufacturing stations are comprised of automatic terminal insertion and testing. On-line testing guarantees the electrical quality and integrity of every stator produced. We can also incorporate magnetism testing of each rotor.  

Measurement, Marking & Traceability

Quality measurements are performed at line speed to capture physical run out for motor balance and dimensional accuracy. Unique product and process information is recorded on each component. Data is also recorded and can be passed to your factory information system or COSMOline for analysis.

Rotor Banding & Magnet Insertion

Permanent magnets are picked and arrayed around a rotor fixture plate. A narrow steel strip is wound around the magnets and fixture to form the rotor band. Subsequently, components are over-moulded and the fixture recycled.

Rotor & Stator Moulding Cells

Injection moulding machines and six-axis robots are integrated to pick and place either rotor or stator components prior to over-moulding. The robot then unloads and desprues the over-moulded components. 

 

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