Motor Assembly

Case Study: Design and Manufacturing of a Motor Assembly for Industrial Automation

Published: February 5, 2020, Category: Industrial Automation

Overview

A leading manufacturer of industrial automation equipment approached us with a requirement for a compact, high-efficiency motor assembly to be integrated into their next-generation robotic actuator system. The motor assembly needed to meet tight tolerances, deliver high torque in a small footprint, and operate reliably under continuous-duty cycles.

Project Requirements

  • Compact design with minimal weight.
  • High torque output with low noise levels.
  • Integrated gearbox for torque multiplication.
  • Sensor feedback for precise control.
  • Robust housing for harsh industrial environments.
  • Thermal management and vibration resistance.
  • Manufacturability at medium production volumes.

Design & Engineering Approach

1. Concept Development

  • Multiple motor types were evaluated: BLDC (Brushless DC), stepper, and servo motors.
  • A BLDC motor with integrated planetary gearbox was selected for its balance of performance, size, and efficiency.
  • CAD models were created for motor, housing, and interface components.

2. Component Selection

  • High-energy neodymium magnets for the rotor.
  • Custom stator winding optimized for torque-density.
  • Low-backlash planetary gearbox (4:1 ratio).
  • Optical encoder for precise speed/position feedback.
  • Thermally conductive but electrically insulating materials for heat dissipation.

3. Prototyping

  • Rapid prototyping via CNC machining and 3D printing.
  • Performance validated using in-house dynamometer testing.
  • Modifications made to improve torque response and reduce vibration.

4. Electronics Integration

  • Custom motor driver PCB developed with overcurrent, thermal, and stall protection.
  • Integrated sensor inputs and CANopen communication protocol.

5. Mechanical Design & Manufacturing

  • Aluminum housing designed for efficient heat sinking and structural integrity.
  • All assemblies performed in-house with precision alignment tools.
  • Tested to withstand IP54 environmental conditions.

Testing & Validation

  • Torque-speed characterization under variable loads.
  • Thermal cycling to verify reliability over time.
  • Shock and vibration tests per IEC standards.
  • EMC compliance to meet CE certification.

Results

  • Final motor assembly delivered 30% higher torque than previous design.
  • Achieved 15% reduction in overall size and weight.
  • Met all thermal and noise specifications.
  • Successful integration into client’s robotic actuator system.
  • Scaled to production volumes of 500 units/month within 90 days.

Conclusion

This project demonstrated our full-scope capabilities—from initial concept through prototyping, validation, and manufacturing. The success of the motor assembly design directly contributed to the client’s product launch, providing them with a performance edge in the competitive automation market.

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