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Bosch Manufacturing Solutions | BMG

eDrive

Electrification is driving a fundamental transformation in the global automotive market, and this trend is particularly evident in China. In 2024, the production and sales volume of new energy vehicles in China continued to grow, ranking first in the world for 10 consecutive years. Bosch is actively promoting the green and low-carbon development of the Chinese automotive market and assisting the transformation of various models in the field of new powertrain systems in the domestic market.

Drive Motors

Bosch Manufacturing Solutions integrates global R&D resources to deliver professional and highly efficient flat wire drive motor assembly solutions. In 2017, Bosch Manufacturing Solutions delivered the first flat wire drive motor assembly line for Chinese market. Until now, Bosch Manufacturing Solutions has cumulatively provided dozens of flexible high volume drive motor production lines which accelerate the development of global new energy vehicle industry.

Bosch Manufacturing Solutions BMG Clamping
BMG Smart Production Lines

Smart Production Lines for Flat Wire Stators

  • Standardized and modular design concept which is compatible for stator with diameter range 150-270mm，slot number range 48/54/72.
  • Equipment quality and safety are compliant CE requirements.
  • Integrate Bosch control systems and MES systems with intelligent software solutions, which achieve production traceability and equipment status monitoring.
BMG Hair-Pin forming station

Hairpin Forming Stations

  • Fully automatic stripping and hair pin forming process which achieves 1s/pin cycle time
  • Numerical controlled stamping process to achieve high precision and stability
  • Integrated inline insulation testing
  • Smart scheduling algorithm which enables flexible co-line production for maximum 18 types of hair pins.
BMG Insertion

Insertion

  • Ultra-high flexibility: Compatible with various complex wire types such as hair pin and i-Pin
  • Process monitor: Inline vision inspection during pin insertion process
Twisting

Twisting

  • Multi-axis NC motion control with intelligent Cam algorithm: Precisely controls Z-axis compensation and rotation of each layer in molds.
  • Twisting tooling is manufactured with special coating process: High strength and long service life.
  • Equipped with pre-inspection station and mold entry guidance: Ensures precise mold entry.
  • Modular design: Enables flexible model changeover.
Laser welding

Laser Welding

  • 3D vision system and high-performance laser source: Equipped with Bosch self-developed vision control system, enabling precise guidance and high-speed flight welding, achieving 0.2 seconds per weld point.
  • Precision automatic clamping device: Ensures the pre-welding state.
  • Welding process energy monitoring system and AI weld quality inspection: Guarantees welding quality.
  • Laser safety protection compliant with CE standards.
Trickling

Trickling

  • Direct current (DC) controlled heating: Capable of rapidly increasing temperature to 45°C within 30 seconds.
  • Self-developed temperature control algorithm: Maintains temperature tolerance within ±3°C.
  • Product platform tilt during impregnation process: Achieves a tilt of -2° to 20° to optimize filling rate.
  • Safe and reliable exhaust and fire suppression systems.
  • Utilizes digital models and key equipment parameter curve fitting: Calculate stator temperature with control precision of ±3°C.
PI Testing

PI Testing

  • Compact design without loading process and cooling process, achieving 50% investment reduction and lower maintenance costs.
  • Suitable for a variety of product models.
  • Capable to detection of assembly errors.
  • 60 seconds cycle time including loading and unloading process, shortened by 50% compared to classic concept.
  • High-speed data acquisition (>200 kHz).
  • Noise and vibration testing.

Small Motors

From traditional internal combustion engine vehicles to today's new energy vehicles, micro motors are indispensable in providing consumers with a safe, comfortable, and intelligent driving experience. Bosch Manufacturing Solutions has been deeply involved in the process development and manufacturing of micro motors for decades, customizing advanced, stable, and efficient non-standard assembly and testing production lines for clients.

BMG Small Motors
BMG CN

Small Motor Production Line

  • Standardized and Modular Design: Rapid model changeover and expansion for new product development
  • Equipment Manufacturing Quality and Safety Systems Compliant with EU Standards
  • Bosch Self-developed Equipment Control Systems and MES Systems, along with flexible and intelligent additional software solutions, enabling full-process traceability of products, process data control, intelligent maintenance, and big data analysis of production and processes
BMG CN

Copper Wire Winding and Forming

  • Constant Tension Servo Wire Feeding System: Tension values can be flexibly set through the program
  • Quick Change of Winding Molds
  • German Rexroth Servo Motors and CNC Control System: Simple process program compilation
  • Automatic or Manual Loading and Unloading
  • Copper Wire Change Prompt, Automatic Shutdown Alarm for Broken or Missing Wire
  • MES Interface Reserved
  • CE Certification
BMG CN

Testing

  • Modular Design: Enables rapid model changeover
  • Compliance with EU Safety Standards
  • Measurement of Micro Motor Performance Parameters: Including torque, speed, noise, etc.
Handling

Handling & Line Concepts

We offer a wide range of robotic and transfer solutions to meet the individual cycle time and handling requirements of our customers. These customized system concepts are validated and optimized at an early stage using digital material flow simulation in order to guarantee the planned manufacturing strategy and production processes.

Handling
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