The team at GP Reeves is dedicated to advancing innovation in the automotive industry through effective dispensing systems. A key focus is optimizing the assembly process for rotors, a vital component in electric motor units. Unlike competitors who rely on less precise methods like trickling, GP Reeves delivers superior precision and efficiency with our advanced dispensing technology. Driven by a passion for continuous improvement and a forward-thinking approach to the mobility sector, GP Reeves remains a leader, powering industry progress with cutting-edge solutions.
Case Summary
A long-standing customer approached GP Reeves seeking a solution for their rotor assembly project. The company was developing a rotor system for electric motor units, intended for use in the drivetrains of both electric vehicles and hydrogen-powered heavy equipment. As a supplier to leading OEMs worldwide, they needed a dispensing system as advanced as their impact on the global transportation industry. GP Reeves was poised to deliver a state-of-the-art solution, aligning with the innovative nature of their groundbreaking work.
The Problem: A Status Quo with Issues
For their production process, the customer required adhesive glue to be applied to the rotor’s cavity pockets before inserting the magnets into the assembly. Traditionally, magnet adherence relied on the trickling method, where material is indiscriminately “trickled” down the sides of the rotor core into the cavities. Although this method is more cost-effective and widely used, it lacks precision and control, often resulting in incomplete coverage of the rotor pockets. This can compromise product quality, reduce rotor longevity, and increase the risk of corrosion. The customer sought a more accurate, effective, and efficient solution to apply material to their rotor components—one that would ensure superior performance and long-term reliability.
The Solution: Reliable Coverage and Increased Efficiency
GP Reeves developed an automated system that ensured precise and consistent coverage of the rotor pockets with the customer’s two-component, heat-cured adhesive. Our engineers meticulously considered the material’s specific properties, including its working time and curing behavior, while tailoring the solution to the customer’s production requirements. Utilizing our airless 2K dispense system, we addressed the challenges of adhesive application by employing nozzles that extended to the bottom of each rotor pocket and coated the walls as the robotic system retracted them. The system was also integrated with a flow meter to verify the exact volume of adhesive applied to each cavity.
By leveraging GP Reeves’ patented airless design, the system ensured accurate material placement, eliminating the risk of air bubbles or missed spots. Our expertise in material handling enabled optimal flow of the customer’s 2K heat-curing adhesive throughout the dispensing process. The system was seamlessly connected to a Fanuc robot, with programming expertly handled by our controls engineering team. Thanks to the system’s precision and reliability, each magnet was securely bonded within the rotor pocket, providing the customer with confidence in the durability and strength of the assembly.
End Result: A Precise System to Drive Mobility Forward
With this innovative dispensing system, GP Reeves achieved precise and uniform adhesive distribution in under 4 seconds across the required surface areas of each rotor. Once the adhesive was accurately applied to the designated rotor slots, magnets were swiftly inserted, and the glue cured efficiently, allowing the rotor assembly to proceed seamlessly. The accuracy and reliability of GP Reeves’ dispensing solution not only significantly reduced motor production time but also enhanced product longevity. The customer was highly satisfied with the increased efficiency and performance of their gluing process, as well as the accelerated speed our system brought to their production line.
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