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In new energy vehicles, the motor and power control system, which replaces the function of the engine in traditional fuel vehicles, accounts for about 10% of the total vehicle value, second only to the battery system. The greater the value it brings, the more assembly technical challenges it faces. How can we efficiently and sustainably improve assembly quality? How can we ensure the qualification of screw tightening in more complex working conditions? What automation solutions for screw feeding and tightening correspond to different types of screws?

Faced with a series of challenging issues arising from the different product characteristics of motor and power control systems, Danikor has launched a variety of innovative assembly solutions to address these problems. These solutions aim to avoid phenomena such as screw jamming, tightening abnormalities, and tightening failures during the assembly process, thereby promoting a stable improvement in the assembly quality of motor and power control products.

The housing part of the motor and power control product not only provides physical protection for the motor system but also withstands external impacts and vibrations to reduce the risk of damage to the motor. During batch production assembly, due to issues such as product manufacturing accuracy, the assembly process also faces multiple challenges.

Challenge 1: Poor Consistency of Housing Products

Pain Point: When the consistency of the housing products is poor, causing inaccurate positioning of bolt holes, the traditional solution is to use 2D camera positioning and recognition. However, this method has spatial angle deviations, and camera imaging not only affects the production cycle but also incurs high hardware costs.

Solution: The external hexagonal blow-and-vacuum floating technology can easily solve this problem. The floating distance can vary according to the changes in the avoidance length, with a deviation range of 0.5-2.5 mm. This technology significantly improves the success rate of hole entry and tightening, and is more cost-effective and efficient.

Challenge 2: Compact Space for Multi-Axis Synchronous Tightening

Pain Point: Due to the large number of fixing bolts on the housing and the compact space, the spatial layout requirements for multi-axis tightening mechanisms are very high. Traditional tightening mechanisms are complex in structure and occupy a large space.

Solution: The integrated tightening module mechanism can now achieve synchronous tightening of up to 12 tightening axes. Compared with traditional mechanisms, it is more compact, with a weight reduction of 20-30%, a width reduction of 60-70%, and a center distance reduction of 60%. The downforce adjustment is more flexible and convenient. Additionally, there are no external moving parts, and the cables are fixed, making it more suitable for integration with robots. This solution is particularly suitable for the installation layout of small spaces and can achieve tightening of bolts with smaller spacing.