(E-MC) Electric motorcycle assembly line

The Electric Motorcycle Assembly Line consists of a floor conveyor system and an auxiliary operation system. The line body runs through the entire assembly workshop, and workers complete operations at each station on both sides of the conveyor line.

The floor conveyor system adopts a slat chain conveyor line. The slat chain is formed by connecting multiple metal plates with hinges to create a continuous annular conveying surface. The slat chain is laid in a ground trench, with its upper surface flush with the ground. The driving device is installed at one end of the slat chain and consists of a motor, a reducer, and a sprocket, driving the slat chain to run at a set speed. A tensioning device is installed at the other end to adjust the slack of the slat chain. Fixtures are fixed on the upper surface of the slat chain to position the motorcycle frame. The frame is placed on the fixture and moves forward with the slat chain. The load capacity of the slat chain is designed based on the weight of the complete vehicle and the fixtures, and the chain and plates are made of steel. The running speed of the slat chain is set according to the production cycle time, and the dwell time at each station is fixed. The distance between stations is determined by the assembly content, and a certain distance is maintained between adjacent stations.

The assembly process is divided into multiple sections. The front section handles frame loading and pre-assembly. Empty frames are transported from the storage area or the previous process to the starting point of the line body and placed on the slat chain fixtures manually or mechanically. Then the frame enters the motor installation station, where workers fix the motor in the middle and lower part of the frame. The motor is delivered to the station side by an independent conveyor line or a suspension conveyor system. Electric tightening tools are used for fastening, and the torque value is specified by the process documents.

The middle section performs electrical system assembly. Workers install the battery pack, controller, wiring harness, and instruments on the frame. The battery pack is heavy, so some stations are equipped with assistive manipulators or lifting devices to help workers with handling and positioning. The wiring harness is routed along the frame, and connectors are plugged into corresponding sockets. The instrument panel is installed at the head position and connected to the wiring harness. After the electrical connections are completed, workers conduct a power-on test at the inspection station to check functions such as motor operation, lights, and instrument display. Test data is recorded at the station terminal.

The rear section carries out the assembly of exterior parts. Workers install body shells, seats, rearview mirrors, fenders, and other components on the frame. Shell parts are produced in the injection molding workshop and delivered to the line side via logistics turnover boxes. Some shell parts are bulky, so dedicated material racks are set up beside the stations, with rack heights designed for easy access by workers. Tires and wheels are installed at independent stations, where workers use special tools to inflate the tires and mount them on the frame. The braking system is assembled before or after tire installation, including brake discs, brake cables, and brake fluid filling.

The final section conducts vehicle commissioning and testing. Workers perform road tests or bench tests on the complete vehicle at the end of the slat chain to check acceleration, braking, steering, and lights. After passing the tests, the vehicle leaves the line at the end of the slat chain and enters the packaging or storage area.

An auxiliary operation system is installed above the line body. Suspension rails are mounted on the workshop ceiling, equipped with pulleys and balancers for hanging pneumatic and electric tools. Air pipes and cables are connected to the tools via spiral tubes or slide rails. Workers pull the tools within the working range, and the tools automatically return to position when released. Some workshops have a material distribution system above the conveyor line, using suspension chains or slide rails to deliver parts from the storage area to the line side, reducing the occupation of ground logistics channels.

The station layout is arranged according to the assembly sequence. Each station is equipped with tool racks, parts boxes, and work instructions. The work instructions display assembly steps and inspection points in graphic form. Material racks are placed beside the stations to store parts and fasteners required for the station. The number of layers and spacing of the material racks are designed according to the size of the parts. Lighting fixtures are installed above the stations, with illuminance values meeting the requirements for fine assembly. Some stations are equipped with station screens displaying production cycle time, quality prompts, and call information.

The control system consists of a PLC and a touch screen. The PLC controls the start, stop, running speed, and positioning accuracy of the slat chain. The touch screen is installed in the central control cabinet or beside the line body, allowing operators to set parameters and view status through the interface. Multiple emergency stop buttons are set on the conveyor line, distributed on both sides of the stations and at the central control position. When a worker triggers the emergency stop, the slat chain stops running, and it restarts after the fault is eliminated and reset. The line body is equipped with audible and visual alarms to indicate equipment abnormalities or shift change information.

The cycle time of the Electric Motorcycle Assembly Line is determined according to the production capacity plan, ranging from tens of seconds to several minutes. The line length is calculated based on the number of stations, station spacing, and workshop dimensions. The width of the slat chain, plate thickness, and drive power are selected according to the load requirements. The track specifications and suspension point spacing of the auxiliary system are determined based on the tool weight and coverage range.

This slat chain conveying method is widely used in the electric motorcycle manufacturing industry. The slat chain provides a continuous ground operation platform, allowing workers to stand in fixed positions to assemble the moving frames. The suspension system provides tool and material support, reducing worker movement distance. All systems operate in coordination through a control program, forming an assembly line for mass production of electric motorcycles.

Supplementary Technical Parameter Table for the Electric Motorcycle Assembly Line