Motor Assembler II - Brush Hand Wind

Motor Assembler II

Motor Assembler II will have a good working knowledge of both past and present product lines and will have demonstrated ability to perform with little or no assistance at least three major tasks/jobs identified in the Motor Assembler I job description. Will diagnose on your own and/or in conjunction with quality causes of malfunctions and take proper corrective action. In addition, will assist in process improvement efforts.

This position will be joining the Kollmorgen team in Radford, VA. Kollmorgen is part of Regal Rexnord.

Essential Duties and Responsibilities

The tasks/jobs include the following:

• Standard Motor Assembler. Assemble all standard motors using assembly drawings, shop travelers, outline drawings, and process sheets (IM). Use bill of material to pull correct parts for the assembly process and record traceability on pick list. Magnetize small field assemblies. Inspect own work, such as end play, to assure the motor meets the drawing and quality requirements. Handle all material to prevent damage and contamination.
• Large Motor Assembler. Assemble all large motors using assembly drawings, shop travelers, outline drawings and process sheets (IM). Use bill of material to pull correct parts for the assembly process and record traceability on pick list. Magnetize large field assemblies using large magnetizer. Mount large assemblies onto horizontal and vertical test stand. Use proper handling to prevent injury and damage to motor assembly. Inspect own work to assure compliance to drawing and quality requirements. Handle all material to prevent damage and contamination.
• Actuator and Higher Level Assembler (HLA). Assemble all actuators and HLA using assembly drawings, shop travelers, outline drawings and process sheets (IM). Use bill of materials to pull correct parts for the assembly process and record traceability on pick list. Use proper handling to prevent injury and damage to motor assembly. Inspect work to assure compliance to drawing and quality requirements. Assemble brakes, encoders, and resolver per drawing.
• Motor Tester. Perform all required mechanical and electrical tests per IM, Test Procedure, and Motor Test Procedure. Perform standard frameless test and standard housed test, must be able to perform testing of large motors, and complex motor drives including resolvers, encoders, brakes, environmental tests, and vibration testing. Operate all test equipment including Goldline auto tester, MATS test station, and back drive station. Complete proper Quality Systems Procedure test data sheet. Ensure motors meet all test requirements.
• Spray Painter. Cleans parts to be painted such as motor assemblies, generators, housings, end bells, and related to ascertain that all parts are free of dirt, grease, oil, and film. Mask all areas to be left unpainted using correct procedure; some methods being masking tape, masking plugs or shield masking. Mix epoxy, lacquer, enamel using proper thinners and reducers. Use correct mist spray for proper coverage and minimum overspray. Be familiar with procedures for degreasing and cleaning which may or may not require painting such as in the case of re-work or customer returned parts or motors. Change filters in spray booths as required to control emission of overspray.
• Winder. Gather correct wire per winding data sheet. Maintain wire, lam and insulator inventory using Kanban. Insulate lamination stack, load parts, and run corresponding programs in winding machine. Unload parts and perform resistance, and other specified tests to determine if armature is ready for next process. Responsible for all fixture changes and/or adjustments to machine parameters such as speed, wire tension, and position offsets to produce quality parts and avoid winding machine damage. May also perform other armature manufacturing processes such as crimping, soldering, varnishing, pressing, polish and coat, sensor assembly, sensor setting, and armature inspection as required. Runs machine winding equipment with custom products or aligns with high frequency of changeover.
• Machine Winder. Gather correct wire per winding data sheet. Set-up winding machine to perform the winding of stator. Perform a crimping operation, sensor setting, sensor assembly, varnish, polish, and coat, press and armature inspection. Perform the resistance test to determine if stator is ready for connect. Various types of stators, such as Goldline and XT, will be wound.
• Encapsulation. Duties include one or more of the following areas: skewing and trickle varnish; motor encapsulation; and varnish (dip and bake). These operations will be performed per established procedures.
• Rotor Assembler. Assemble all rotors by reading blueprints and checking dimensions with appropriate measuring tooling. Pull correct parts and maintain control of inventory. Will include turning and balancing.
• Core Processing. Duties include bonding and stacking of laminations, sandblasting, and deburring cores, fluidize bed coating, and spray painting of cores. In preparation and performance of job requirements, it is necessary to use, read and interpret drawings, shop travelers, calipers, and micrometers, as well as applicable gauges and fixtures, paint booth, sandblaster, file, sander, ovens, and buffer. Must have training for packing RCRA Hazardous Waste in DOT approved containers prior to shipment. OSHA/EPA/DOT training regarding the Hazardous Materials Building.
• Magnet Processing. Perform all necessary operations for the mechanical and electrical strength characteristics of yoke-ring sub-assemblies. The operations consist of cleaning and deburring, bonding, banding, balancing, and spray painting of field assemblies. Shop travelers and prescribed procedures must be followed. Use of calipers, micrometers, and applicable gauges and fixtures. Various operations performed using pressure washer vibratory finishing equipment, sandblaster, ovens, clean cabinets, balancers, banding machines, paint booth, spray guns and various hand tools. Job requires mixing of various bonding and paint materials. Must be trained in packing RCRA Hazardous Waste in DOT approved containers prior to shipment. OSHA/EPA/DOT training regarding the Hazardous Materials Building.
• Lamination Manufacture. Perform operations to complete lamination manufacture, includes press, set-up, and running blanking and notching presses. Heat treat and inspect stamped parts.
• Undercut/Debur. Perform a variety of duties involving hand and machine operations to prepare parts and sub-assemblies. Work from drawings, operation sheets, and prescribed published procedures to perform hand deburring using visual aids and tools prescribed. Select and mount fixtures and accessories to small lathes and milling machines to undercut commutator slots after machining. Operate Laser undercut machine to perform undercutting operation; balance armatures and stators. Perform rework such as Patching of armatures and precision deburr.
• Commutation Devices. Refer to drawings and operation sheets to assemble brush spring segments. Use micrometer to determine material is correct width and thickness. Spot weld clips to spring; clean and remove burrs. Sport weld terminals to spring as required. Solder brush block to clip; clean and remove excess solder wire to springs for molded rings. Sub assembly operation requires use of micrometers, venier calipers, punch press, forming press, spot welding machine, resistance soldering machine, vapor hone machine, soldering irons, microscope, magnifying glass, solder & tweezers, perform sensor setting, heat treat, inspection of solder joints, deflash operation, and transfer mold.

All of the above tasks/jobs would require keeping tools and work area in a clean and orderly condition. In addition, must observe prescribed safety precautions. Will work on other tasks/jobs as deemed necessary by coordinator.

Education and Experience Requirements

• High School Diploma or GED
• Good written and verbal communication skills and basic knowledge of arithmetic; simple use of formulas, charts, tables, drawings, specifications, schedules, wiring diagrams, and adjustable measuring instruments; posting, preparation, interpretation, use and checking of reports, forms, records, and related.
• Requires the use of judgment to plan, perform, and make decisions as to the sequence of setups, operations, and processes within the limitations of recognized or standard methods.
• Continuous mental and visual attention; usually diversified operations requiring constant alertness or activity.
• Must be self-motivated and self-directed.
• Minimum of three years of progressively complex manufacturing experience.

Physical Demand and Work Environment:

Physical Demands:

• Lifting over 50 pounds.
• Standing for long periods of time.
• Using pressure to push and pull.
• Bending, stretching, reaching high and low locations.

Restrictions imposed by federal export control laws may limit this job opportunity to candidates who are a "U.S. Person", which includes U.S. citizens, U.S. nationals, U.S. permanent residents, individuals granted asylum in the United States, and refugees in the United States, or who otherwise can qualify for a license that permits them to hold the position.