MotoE Rotor Assembly Optimization

THE CHALLENGE
Managing the critical rotor insertion phase during assembly, where strong magnetic attraction poses a significant risk of finger crushing for the operator and can damage the composite banding of the magnets. The objective was to ensure maximum operator safety while preserving the integrity and reliability of the rotor.

THE SOLUTION
Design and development of a dedicated assembly tool that enables controlled and safe insertion and removal of the rotor.
The system consists of a mounting plate fixed to the motor base, and a threaded guide rod precisely centered on the inner ring of the bearing. This configuration ensures accurate guidance of the rotor during assembly, counteracting the effects of magnetic attraction and allowing the component to be positioned smoothly and safely.

RESULTS

• Enhanced Operator Safety
  The guided insertion process eliminates the risk of finger crushing caused by sudden magnetic forces.
• Rotor Protection 
  Damage to the magnet composite banding is prevented, ensuring long-term reliability and performance.
• Improved Repeatability and Precision
  Assembly quality is enhanced, with reduced process variability and greater consistency across production.