ADVANCED MANUFACTURING
STEPPER MOTOR PRODUCTION
A case study in taking a program from concept to production: Fraen designed and operated a high-speed, automated manufacturing system for instrumentation-oriented MM39 stepper motors, that maintained world-class quality levels through the integration into the assembly process of 100% in-line functional testing.
This program reflects Fraen's capability in delivering scalable, electromechanical production systems, from project management with industry partners of custom machine buildouts to real-time production process diagnostics and performance tracking.
1.Manufacturing System and Output
The operation ran across multiple automated cells, each of which combined coil winding, stator assembly, final assembly, 100% in-line functional testing, and packaging.
2.5s
Average cycle time per motor
100%
In-line functional testing
1.2 Nmm
Minimum output torque verified
2.Testing and Quality Control
Each motor was tested at multiple points, and all failures were automatically and immediately rejected from the line.
Resistance Test
Each bobbin coil was charged and its resistance measured to ensure it was within the expected range.
Induced Voltage Test
Upon insertion of the in-line magnetized rotor gear, the WIP motors were energized to drive the magnet rotor in both directions to ensure balance and functionality.
Torque Test
100% of motors were tested to ensure a minimum output torque of 1.2 Nmm. Every 15 minutes, the three motors in the tester were instead run up to their maximum output torque, characterizing the overall motor population's capability — typically 1.6–1.7 Nmm.
Vibration Test
100% of motors were placed into isolation nests and powered through a full 270 degree sweep in both directions, with multiple noise & vibration aspects of each motor evaluated against established process limits.
3.Process Design and Operation
The production system was jointly designed and engineered by Fraen and a close industry partner, with much emphasis placed upon efficiency, uptime, repeatability, and adaptability.
- •Real-time system feedback at each station
- •Minimal manual handling after initial loading
- •Easy access for maintenance and configuration changes
- •Continuous data tracking on yield, cycle time, and faults
Fraen maintained full control of the system, from initial concept through long-term production, demonstrating deep capability in high-volume, precision manufacturing.