PROCESS MOTOR EB SAMPLE
MOTOR KANGPING VN: 742127012
DEPARTMENT: NPI
Date: Feb.16th.2021
Prepare: Felix
GENERAL CONTENT
OVERALL INFORMATION
1
2
5
5/25/2023
PRODUCT DRAWING
3
PRODUCT OVERVIEW
4
PROCESS OVERVIEW
IMPROVEMENT POINT
NPI @ Techtronic Industries Vietnam
2
1. OVERALL INFORMATION
SUPPLIER’S INFORMATION
SUPPLIER NAME: KANGPING VN
ADRESS: 28 Dan Chu Street, VSIP 2 Industrial Park, Hoa Phu Ward, TDM, Binh
Duong
COUNTRY: Vietnam SUPPLIER PERSONEL PARTICIPATING
Ms. Fiona
Mr. Henry
Felix-NPI
Michael-NPI
BEN-SQE
Email: fiona@chinahighspeed.net
Email: mc-sale@vnkangping.com
VISITORS PERSONEL
Email: Synam.ho@ttigroup.com.vn
Email:
Huutan.Nguyen03@ttigroup.com.vn
Email: Ben.Zhong@ttigroup.com.vn
MOTOR INFORMATION
EB Sample Motor 292349001 (Lot Mar.09th 2022)
© Techtronic Industries Co. Ltd. All rights reserved.
3
2. PRODUCT DRAWING 292349001
Motor Drawing
5/25/2023
NPI @ Techtronic Industries Vietnam
4
3. PRODUCT OVERVIEW
Stator
5/25/2023
Rotor
NPI @ Techtronic Industries Vietnam
Motor
5
4. PROCESS OVERVIEW
Insert
commutator
Rotor integration
testing
Welding
A02
A01
A03
A04
A05
Fixative wire
Winding
Insert
magnet
Rotor
balancing
Add glue to
rotor slot
A06
A07
A08
A09
Turning
commutator
Add varnish
Ball bearing
press
A10
A11
Insert washer
A12
Visual check
Ball bearing
press
R01
R02
R04
R03
Add glue
magnet
Insert rotor
to stator
magnetic
flux loading
M02
M01
M03
Dimension check
M04
Caulking motor
M05
Test with
load
Running
motor
Flux ring
press
Insert base
cover
M06
Insulation
test
M07
M08
No load
test
NOTE:
A: Rotor process
R: Stator Process
M: Motor assembly Process
5/25/2023
NPI @ Techtronic Industries Vietnam
M09
Motor
engraving
M10
Low voltage
test
M11
M12
Visual check
6
A01- Insert commutator
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
Process Product
A04
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Add glue to
rotor slot
Check result
A11
Ball bearing
press
A12
Visual check
Station’s requirement:
 The commutator angle 18.5° ~19.5°
 Actual: 19.394/19.191 -> OK
 Pull out force of commutator 40Kgf Min
 Actual: 215/270-> OK
Run_out of shaft
 Twist torque of commutator 1N.m Min
 Actual: 3.09/2.28-> OK
 The commutator inserting dimension 64.9~65.1
 Actual: 65.03/65.02 -> OK
© Techtronic Industries Co. Ltd. All rights reserved.
Pull out force
Twist torque
7
A02- Winding
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Winding rotor
Winding setup
Rotor winding sample
Ball bearing
press
A12
Visual check
Station’s requirement:
 The winding spec Ø0.4*31T
 Actual: Ø0.4*31T -> OK
 Tensile winding force 7~13 N
 Actual: 8.0/8.0-> OK
 Resistance of rotor 0.1473~0.173Ω
 Actual: 0.1645/0.1576-> OK
Tensile force
Resistance rotor
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
8
A02- Winding
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
Ball bearing
press
Spray test
A05
Rotor integration
testing
A06
Add varnish
Result test
Check deformed winding
A12
Visual check
Station’s requirement:
 The test spec at 24VDC, 60S, 10mA Max
 Actual: OK
 The deformed of wire 5% Max
 Actual: 1.2/1.3-> OK
A07
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
9
A03- Welding
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
Ball bearing
press
Welding rotor
Rotor welding sample
Welding setup
A12
Visual check
A06
Add varnish
A07
Add glue to
rotor slot
Station’s requirement:
 Resistance of rotor 0.1473~0.173Ω
 Actual: 0.1587/0.1608-> OK
 The dimension stick welding 0.35~0.4mm
 Actual: 0.38-> OK
Resistance check
© Techtronic Industries Co. Ltd. All rights reserved.
Resistance result
10
A04- Fixative wire
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Add glue to
rotor slot
Ball bearing
press
A12
Fixative wire of rotor
Rotor wire after fixative
Visual check
Station’s requirement:
 The coil heigh 1.0mm Min compare with washer surface
 Actual:1.11/1.17> OK
 Check visual of rotor
 Actual: OK
© Techtronic Industries Co. Ltd. All rights reserved.
11
A05- Rotor integration testing
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
Rotor integration
testing
A06
Add varnish
Visual check
Result test- OK Sample
Station’s requirement:
 Resistance of rotor 0.1473~0.173Ω
 Actual: 0.1587/0.1608-> OK
 Check Hight voltage 600VAC, 1s/1mA Max
 Actual: OK
 Check Impulse 600V, 15% Max
 Actual: OK
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
Result test- NG Sample
Master NG
A07
A12
integration testing
Master OK
A05
Ball bearing
press
12
A06- Add varnish
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
Add varnish rotor
A04
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Rotor sample-top side
Rotor sample- bottom side
A11
Ball bearing
press
A12
Visual check
Station’s requirement:
 The weight of varnish 2.8~3.2g
 Actual: 3.05/3.02-> OK
 The weight of glue fixed 1.0~2.2g
 Actual: 1.40/1.41  OK
 Cutting rotor and check varnish inside
 Actual: OK
Rotor cutting check varnish inside
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
13
A07- Add glue to rotor slot
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
Add glue in rotor slot
Rotor sample- added glue
Check length add glue
Ball bearing
press
A12
Visual check
Station’s requirement:
 The weight of glue 0.5~1.1g
 Actual: 0.627/0.546-> OK
 The length add glue
 Actual: 8.26/9.62  OK
 Temperature dry 135°C ~ 155°C
 Actual: 145°C  OK
Rotor dry soaking
A07
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
14
A08- Turning commutator
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Add glue to
rotor slot
Ball bearing
press
A12
Visual check
Turning commutator
Rotor sample- after turning
Station’s requirement:
 The length of turning 9.2mm Min
 Actual: 9.52/9.48-> OK
 Roundness of commutator 4.0ɥm Max
 Actual: 2.74/2.63  OK
 Bar to bar 2.0ɥm Max
 Actual: 0.93/1.21  OK
 Diameter turning commutator Ø14.8 Min
 Actual:14.98/15.0 OK
 Roughness of commutator Ra 0.6~1.0ɥm
 Actual:0.896/0.887 OK
© Techtronic Industries Co. Ltd. All rights reserved.
15
A09- Rotor balancing
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Rotor balancing
Master NG balancing
Ball bearing
press
A12
Visual check
Station’s requirement:
 Unbalance spec 30mg Max
 Actual: 19.8/18.0-> OK
 Deep cutting 1.0mm Max
 Actual: 0.82/0.81  OK
 The length cutting 7.4mm Max
 Actual: 6.12/5.43  OK
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
16
A10 A12- Insert washer, press bearing and visual check
A01
A08
Insert
commutator
Turning
commutator
A02
Winding
A09
Rotor
balancing
A03
A10
Welding
Insert washer
A04
A11
Fixative wire
A05
Rotor integration
testing
A06
Add varnish
A07
Insert washer to rotor
Ball bearing
press
A12
Visual check
Press ball bearing rotor
Station’s requirement:
 Insert washer prevent oil to rotor at commutator side.
 Actual: OK
 Dimension press ball bearing 70.4~70.6mm
 Actual: 70.55/70.52  OK
 Visual rotor check
 Actual: OK
Add glue to
rotor slot
© Techtronic Industries Co. Ltd. All rights reserved.
17
R01- Insert magnet
R01
Insert
magnet
R02
Add glue magnet
R03
Ball bearing
press
R04
magnetic flux
loading
Insert magnet
Stator ass’y magnet
Check deep magnet
Check inner diameter of magnet
Station’s requirement:
 The deep of magnet 18.3~18.9mm
 Actual: 18.62/18.61 -> OK
 Inner diameter of magnet 31.5mm Min
 Actual: 31.58 -> OK
Gauge check
© Techtronic Industries Co. Ltd. All rights reserved.
18
R02- Add glue magnet
R01
Insert
magnet
R02
Add glue magnet
R03
Ball bearing
press
R04
magnetic flux
loading
Add glue fix magnet and V clip
Stator added magnet glue
Before add glue
after add glue
Station’s requirement:
 The weight of glue 0.1~0.3g
 Actual: 0.131/0.176 -> OK
 Temperature for dry glue 135~155°C
 Actual: 145°C -> OK
 Time for dry glue 45~60 minutes
 Actual: 60 minutes -> OK
© Techtronic Industries Co. Ltd. All rights reserved.
19
R03- Ball bearing press
R01
Insert
magnet
R02
Add glue magnet
R03
Ball bearing
press
R04
magnetic flux
loading
Press ball bearing to stator
Add glue to stator at bearing area
Stator pressed bearing
Station’s requirement:
 Dimension press bearing 49.5~49.7mm
 Actual: 49.57/49.60 -> OK
 The weight of bearing glue 0.06~0.13g
 Actual: 0.09/0.115 -> OK
 Pull out force of bearing 70Kg Min
 Actual: 187/190-> OK
© Techtronic Industries Co. Ltd. All rights reserved.
20
R04- magnetic flux loading
R01
Insert
magnet
R02
Add glue magnet
R03
Ball bearing
press
R04
magnetic flux
loading
Magnetic flux loading
Stator pressed bearing
Master NG flux
Station’s requirement:
 The voltage for magnetic flux loading 2000V
 Actual: 2000V -> OK
 The flux of stator 7.3~7.6 mWb
 Actual: 7.45/7.50 -> OK
 Visual magnet no break
 Actual: OK
© Techtronic Industries Co. Ltd. All rights reserved.
21
M01 M03 - Insert rotor to stator
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
M06
Insulation
test
Motor
engraving
Assembly rotor to stator
Insert brush holder to cover
Motor assembly
M12
Visual check
Station’s requirement:
 The rotor and base assembly correct position and no deformed
 The carbon brush no broken and no stuck
 Actual: OK
M07
Running
motor
© Techtronic Industries Co. Ltd. All rights reserved.
22
M04, M05- Caulking motor and press flux ring
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
M06
Insulation
test
M07
Running
motor
Motor
engraving
Press flux ring to motor
Motor insert flux ring
M12
Visual check
Station’s requirement:
 Press force caulking motor 70Kg Min
 Actual: 130/150 -> OK
 Caulking 8 positions of motor
 Actual: 8 positions -> OK
 Dimension press flux ring 4.6 ~5.4mm
 Actual: 4.91/4.82-> OK
© Techtronic Industries Co. Ltd. All rights reserved.
23
M06, M07 - Insulation test, Running motor
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
M06
Insulation
test
M07
Running
motor
Motor
engraving
Motor insulation test
M12
Visual check
Station’s requirement:
 Insulation test 600VAC, 1s,1mA
 Actual: OK
 Insulation resistance 500V, 10M ohm Min
 Actual: OK
 Running motor at 20.5VDC, 60s
 Actual: OK
© Techtronic Industries Co. Ltd. All rights reserved.
24
M08 - No load test
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
M06
Insulation
test
M07
Motor
engraving
M12
Visual check
No load test motor
Master NG no load
Station’s requirement:
 No load spec at 20.5VDC, 1.7A Max
 Actual: 0.98/0.97 -> OK
 The speed of motor 10800 ~13200rpm
 Actual: 12163/12410 -> OK
 The rotation of motor CCW
 Actual: CCW -> OK
Running
motor
© Techtronic Industries Co. Ltd. All rights reserved.
25
M09-M10 - Test with load, low voltage
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
M06
Insulation
test
M07
Running
motor
Motor
engraving
M12
Visual check
Motor Test
Station’s requirement:
 Current with load spec at 20.5VDC, 7.5A Max
 Actual: 5.31/5.55 -> OK
 The speed of motor 9720~11880rpm
 Actual: 10163/10414 -> OK
 Fan load 80*25mm
 Actual: OK
 Low voltage test at 1VDC motor rotate
 Actual: OK
© Techtronic Industries Co. Ltd. All rights reserved.
26
M09 - Motor engraving
M01
M08
Insert rotor
to stator
No load test
M02
Dimension check
M09
Test with
load
M03
M10
Insert base
cover
Low voltage
test
M04
M11
Caulking motor
M05
Flux ring press
Motor
engraving
M12
Visual check
Motor engraving
Station’s requirement:
 Part no for engraving 742127012 01
RS7310PM4031
20.5VDC
KPVNXXXXXX
M06
Insulation
test
M07
Running
motor
Motor sample engraving
 Actual: OK
 Check visual of motor
 Actual: OK
© Techtronic Industries Co. Ltd. All rights reserved.
27
5. IMPROVEMENT POINT FOR BUIL EB SAMPLE
© Techtronic Industries Co. Ltd. All rights reserved.
28
5. IMPROVEMENT POINT FOR BUIL EB SAMPLE
© Techtronic Industries Co. Ltd. All rights reserved.
29
5/25/2023
NPI @ Techtronic Industries Vietnam
30