Automatic Welding & Testing Machine

Model BKD-WT-01

Spot-welds the commutator tangs and runs a high-voltage insulation test on the same station, so a bad weld or an insulation fault is caught before the armature reaches wedging and turning.

Cycle time: ≤ 7 s
Hipot test voltage: 1.5 kV
Electrode force: 450–1500 N

Applicable armatures

Motor types: Brushed DC and universal motor armatures
Armature OD: Φ12–50 mm
Shaft diameter: Φ3–15 mm
Shaft length: ≤ 200 mm
Wire diameter: Φ0.08–1.2 mm

Specifications

Performance
Parameter	Value	Unit
Cycle time	≤ 7	s/pc
Output	≈ 510	pcs/h
Changeover	30	min
Operations in one station	Spot welding + hipot test
Electrode force	450–1500 (adjustable)	N
Electrode cooling	Closed-loop water

Precision
Parameter	Value	Unit
Hipot test voltage	1.5	kV
Hipot dwell time	1.5	s
Leakage current resolution	0.001	mA

Electrical & pneumatic
Parameter	Value	Unit
Power supply	AC 380 V ±10% / 3 ph / 50–60 Hz
Rated power	12	kW
Air pressure	0.4–0.6	MPa

Dimensions & weight
Parameter	Value	Unit
Footprint (L×W×H)	≈ 2 000×1 100×1 700	mm
Weight	400	kg
Finish	RAL 9003 signal white

Control
Parameter	Value	Unit
PLC	Mitsubishi FX5U
HMI	Weinview 10"
Servo axes	2

How it works

1Armatures arrive on the conveyor and an indexing plate brings each one to the welding station.
2Water-cooled electrodes spot-weld every commutator tang at a set force between 450 and 1500 N.
3The same station applies 1.5 kV between winding and core and reads the leakage current.
4Passing armatures continue down the line; failures are diverted to the reject chute.

Standard configuration

Servo drive package and safety guarding with interlocked doors
PLC with touch-screen HMI, recipe storage per armature model
One set of tooling for the armature model agreed at order
Operation and maintenance manual, recommended spare parts list

Options

Additional tooling sets for further armature models
Data logging with CSV export or MES interface
Automatic loading and unloading, conveyor for line integration
Spare parts package for 12 or 24 months of production

Video

Related projects

Vietnam · Power tools · Universal motor armature, 900 W

A second armature line for a power-tool motor plant in northern Vietnam

Nine stations replacing a part-manual line, commissioned in eleven weeks. First-pass yield at final test rose from 94.2% to 98.7%.

Read the case →Example case study. Figures are placeholders.

All machines in this process

Dual-servo commutator spot welding machine

Station 06

Commutator Welding

Dual-Servo Commutator Spot Welding Machine

BKD-SW-02

Cycle time: ≈ 6.5 s / 10 tangs
Wire diameter: Φ0.06–1.5 mm