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Automated Motor Housing Press Design
Automating a hot stator press operation to eliminate manual handling of thermally expanded components and improve assembly accuracy.
The Problem
A motor manufacturer required workers to manually pick hot stators directly from an oven conveyor — wearing gloves — and hand-align them into rotors before pressing. The process created risk of thermal burns, inconsistent alignment, and assembly errors from manual handling variation.
The Solution
Designed a full SPM in SolidWorks that integrated directly with the existing conveyor. The stator exits the oven conveyor and is received by the machine structure. A pneumatic press pushes the stator down into the rotor with controlled force and speed. Alignment is geometry-based — both stator and rotor have a single valid orientation, so the platform self-aligns on loading.
Key Design Decisions
Geometry-based platform with spring-loaded rotation mechanism — stator platform rotates under press load to allow controlled descent, then returns to original orientation via spring return
Pneumatic press selected for controlled, repeatable force application — critical for consistent interference fit without damaging components
Second pneumatic piston integrated to transfer the assembled motor directly to an engraving station for serial number etching — eliminating a separate manual transfer step
3D scan of existing environment used to constrain machine envelope and conveyor integration
What Was Built
Working prototype was built and validated — demonstrated more accurate stator-rotor assembly and eliminated direct worker contact with hot components.
Key Skills: SolidWorks, SPM Design, Pneumatics, Mechanism Design, DFM, Concept Development, Prototype Validation
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