A loyal customer came to GP Reeves seeking a solution for their rotor assembly project. The company was developing a rotor system that would work for electric motor systems, which would be involved in the drivetrains of both electric vehicles and hydrogen powered heavy equipment vehicles. Their motors, which are found in the vehicles of top OEMs all over the globe, needed a dispensing system as innovative as their impact on the transportation industry.
The Problem: A Status Quo with Issues
For their production, adhesive glue was required in the cavity pockets of the rotor before its magnets could be placed in the overall component. In the past, most methods of magnet adherence had utilized trickling, an uncontrollable and imprecise method where material is “trickled” down the sides of the rotor core and into the cavities. This method may be less expensive and more well-known, but there’s no guarantee that the rotor pockets will receive full coverage – leading to low product quality, less rotor longevity, and an increased likelihood of corrosion. The customer sought a better way to get material onto their rotor components that would prove to be more accurate, effective, and efficient.
The Solution: Reliable Coverage and Increased Efficiency
GP Reeves created an automated system that repeatedly ensured the surface area of the rotor pockets would be accurately covered with the customer’s two-component heat cured glue. Our engineers worked to ensure the material’s unique characteristics would be considered, accounting for such things as material working time, curing properties, and the needs of the customer. In the end, the team at GP Reeves alleviated the challenges of the company’s adhesive application with our airless 2K dispense system. The solution utilized nozzles that went to the bottom of each pocket cavity and coated the walls of the pocket as the robotic system raised the associated nozzles back up. The dispensing unit was combined with a flow meter which verified the amount of adhesive glue dispensed in each cavity.
The system utilized GP Reeves’ patented designs to ensure only airless material was delivered, ensuring there would be no skipped material placements or inaccuracies due to air bubbles. Our team’s material expertise also established methods to promote the proper flow of the customer’s 2K heat-curing material as it passed through the system. This unit was then connected to a Fanuc robot and programming was set up by our skilled controls engineering team. Due to the reliability and efficiency of the dispensing unit, a magnet could then be firmly secured into each cavity, and the customer could be confident about the magnet’s strong position and hold within the rotor pocket.
End Result: A Precise System to Drive Mobility Forward
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