Method and system for assembling a rotor stack for an electric motor

A method for assembling a plurality of rotor cores of an electric converter by a central robotic system, the method comprising:

• providing the central robotic system that includes a core controller, an insert assembly robotic (IAR) system that includes an IAR controller, and a central controller;
• placing a rotor core of the plurality of rotor cores on a mandrel by the central robotic system, wherein the rotor core further comprises a plurality of cavities;
• employing a first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller;
• placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the IAR system by gripping, at a first orientation, one or more magnetizable inserts from the plurality of magnetizable inserts by a robotic arm of the IAR system;
• and aligning and positioning, at a second orientation different from the first orientation, the one or more magnetizable inserts at one or more cavities among the plurality of cavities based on a second force control feedback detected by the IAR controller of the IAR system;
• and
• adjusting a movement of the robotic arm of the central robotic system based on the first force control feedback so that a detected force coincides with a defined value or profile.

A method for assembling a plurality of rotor cores of an electric converter by a central robotic system, the method comprising:

• providing the central robotic system that includes a core controller, an insert assembly robotic (IAR) system that includes an IAR controller, and a central controller;
• placing a rotor core of the plurality of rotor cores on a mandrel by the central robotic system, wherein the rotor core further comprises a plurality of cavities;
• employing a first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller;
• placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the IAR system employing a second force control feedback;
• and
• adjusting a movement of a robotic arm of the central robotic system, an insert assembly robot of the IAR system, or a combination thereof based on the first force control feedback, the second force control feedback, or a combination thereof so that a detected force coincides with a defined value or profile.