1. Scope
Targeting mass‑production scenarios of coreless motors for humanoid‑robot joints, this document classifies automated production lines into three tiers: Basic Level, Advanced Level and Benchmark Level, from three dimensions: process precision, flexible manufacturing and quality control. It provides reference for motor manufacturers in production‑line upgrading planning.
2. Core Capability Requirements for Each‑Tier Production Line
Basic‑Level Line
Adopts a semi‑automatic winding solution with manual assistance for wire arrangement. Winding‑turn deviation is controlled within 1 turn. The welding process mainly relies on manual spot welding, and weld quality is verified by sampling inspection.
Equipment is only compatible with a single product specification. Tooling needs complete disassembly for model changeover, and commissioning usually takes more than 4 hours. Quality management only supports batch filing with process parameters recorded in paper documents. It fits enterprises for new‑product sampling and small‑scale pilot production.
Advanced‑Level Line
Equipped with full‑automatic servo winding mechanism adopting open‑loop tension control, with winding‑turn deviation limited to 0.5 turn. Independent‑station automatic laser‑welding equipment is deployed, followed by 100 % manual visual inspection after welding.
The production line supports 3‑5 stator specifications. Modular tooling simplifies changeover procedures, cutting single‑model‑switch commissioning time down to 2 hours. Process‑step data is collected during manufacturing to realize batch‑level product traceability. It is suitable for manufacturers with stable medium‑and‑small‑batch orders.
Benchmark‑Level Line
Features high‑precision wire‑arrangement mechanism and closed‑loop tension‑control system. Winding‑turn deviation is controlled within 0.2 turn, and wire‑arrangement flatness error shall not exceed 0.01 mm. Integrated fiber‑laser circular‑splicing welding is applied, equipped with real‑time thermal‑imaging monitoring system, and stator roundness is automatically inspected post‑welding.
All process parameters are digitally stored, together with quick‑change tooling; model‑switch commissioning takes no more than 30 minutes. A full‑chain single‑unit data‑binding system is established. All process parameters of every single motor can be retrieved for traceability to satisfy high‑end‑customer supply‑chain‑audit standards. It serves mass‑volume large‑scale production for leading manufacturers.
3. Suggested Production‑line Upgrade Roadmap
New entrants are recommended to build basic‑level lines first to stabilize core‑process performance and complete sample validation. Manufacturers with steady orders may upgrade to advanced‑level lines, focusing on optimizing winding and welding to reduce manual dependency. Leading supply‑chain enterprises can build digital production lines against benchmark‑level standards to meet quality‑delivery requirements for high‑volume humanoid‑robot manufacturing.
4. Supporting Solutions
Xingte Technology supplies tier‑matched precision winding equipment for coreless motors, laser circular‑splicing welding units and turn‑key line‑integration solutions. It supports phased production‑line upgrading, with auxiliary process debugging and operator training services to help lines quickly reach mass‑production targets.
