Motor Assembler

Motor Assembler

The Motor Assembler is responsible for one or more of the following duties in the assembly of motors.

Essential Duties and Responsibilities

• Motor Assembler: Assemble all types of motors by reading and interpreting specification sheets, assembly drawings, outline drawings, and hook-up drawings. Perform small precision assembly and assembly of large units as required. Fabricate or form parts, coils, or structures according to specifications, using drills, calipers, cutters, or saws. Mark serial identification and maintain traceability records. Use bill of material to pull correct parts for the assembly process.
• Motor Tester: Perform all required mechanical and electrical tests per IM, Test Procedure, and Motor Test Procedure. Abide by all safety regulations in testing procedures. 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. Maintain current paint inventory.
• 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. May perform fixture changes and/or adjustments to machine parameters such as speed and wire tension if required per job instructions. May also perform other armature manufacturing processes such as crimping, soldering, varnishing, pressing as required. Runs machine wind in a high volume/low mix products.
• Machine Winder: Gather correct wire per winding data sheet. Set-up winding machine to perform the winding of stator. Perform the resistance test in order to determine if stator is ready for connect. For Brushless units, units may be machine or hand wound. May also perform a crimping operation, sensor setting, sensor assembly, varnish, polish and coat, press and armature inspection. Various types of stators, such as Goldline and XT, will be wound. Maintain wire and/or lam inventory thru the use of a Kanban.
• Encapsulation: Duties include one or more of the following areas: skewing and motor encapsulation; and varnish (dip and bake); sub assembly of motor components, patch, press windings, pre-test armatures, and cleaning (after encapsulation and varnish). These operations will be performed per established procedures and router instructions.
• Rotor Assembler: Assemble all rotors by reading and interpreting blueprints and checking dimensions with appropriate measuring tooling. Fabricate or form parts, coils, or structures according to specifications, using drills, calipers, cutters, or saws. Pull correct parts and maintain control of inventory. Will include turning and balancing.
• Core Processing: Duties include bonding and stacking 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, sandblast, 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 operation 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.
• Lams and Commutator Bar Processing: Perform operations to complete all laminations, end insulators and commutator bars beginning with purchased bar blanks or raw material. Responsibilities also include insulation of cores which require a powder coating operation, wave solder, tumble debur, powder coating insulation and lamination and commutator bar inspection.
• 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.
• 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. Spot weld terminals to spring as required. Solder brush block to clip; clean and remove excess solder from brush and spring assembly. Inspect, sandblast or vapor hone when necessary. Position and solder lead wire to springs for molded rings. Sub assembly operation will require 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, transfer mold

Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Working Relationships: Coordinate with other associates within cell and supervisor. Some positions include handing off completed work to next cell in assembly process.

Education and Experience Requirements

• High School Diploma or GED
• Knowledge of principles and processes for providing customer and personal services. This includes customer needs assessment, meeting quality standards for services, and evaluation of customer satisfaction.
• Knowledge of administrative and clerical procedures and systems such as word processing and managing files and records.
• Good written and verbal communication skills and basic knowledge of arithmetic.
• 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.
• Self-motivated and capable of completing tasks without supervision.
• Being careful about detail and thorough in completing work tasks.

Physical Demand and Work Environment:

The physical demands described here are representative of those that must be met by an employee, with or without reasonable accommodation, to successfully perform the essential functions of this job:

While performing the duties of this job, the employee is regularly required to use hands to finger, handle, or feel; reach with hands and arms; and talk or hear. The employee frequently is required to stand, walk, and sit. The employee is occasionally required to climb or balance; stoop, kneel, crouch, or crawl. The employee must occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, and ability to adjust focus.

*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.

Internal Career Movement Guidelines