Manufacturing overview · Typical process
60 / 80 / 130 mm square flange · 220 V AC or 48 V DC bus · 200 W–1.5 kW
The workhorse of machine automation: permanent-magnet synchronous motors with a 23-bit absolute encoder, low or medium rotor inertia, an optional holding brake and IP65/67 sealing. A concentrated-winding stator, skewed NdFeB rotor and precise encoder alignment give low cogging and accurate positioning. 48 V low-voltage versions on 60 mm flanges share the same construction with a lower-voltage winding.
✓ Expert reviewed All content on this page has been reviewed by a senior motor engineer.
Click a model for full specifications and curves.
| Model | Voltage | Rated power | Rated torque | Rated speed | Current | Rated efficiency | Body length |
|---|---|---|---|---|---|---|---|
| MS1H1-20B30CB-A331R-INT | 220 V | 200 W | 0.637 N·m | 3,000 rpm | 1.5 A | — % | 75.5 mm |
| MS1H1-40B30CB-A331R-INT | 220 V | 400 W | 1.27 N·m | 3,000 rpm | 2.5 A | — % | 93 mm |
| MS1H1-75B30CB-A331R-INT | 220 V | 750 W | 2.39 N·m | 3,000 rpm | 4.4 A | — % | 107.3 mm |
| MS1H3-85B15CB-A331R-INT | 220 V | 850 W | 5.41 N·m | 1,500 rpm | 6.6 A | — % | 142 mm |
| MS1H3-13C15CB-A331R-INT | 220 V | 1.3 kW | 8.28 N·m | 1,500 rpm | 10.5 A | — % | 157 mm |
| ELVM6040V48FH-B25-HD | 48 V | 400 W | 1.27 N·m | 3,000 rpm | 10 A | — % | 90.1 mm |
| SMC60S-0020-30MAK-5DSU | 48 V | 200 W | 0.637 N·m | 3,000 rpm | 5.7 A | — % | 80 mm |
| SMC60S-0040-30MAK-5DSU | 48 V | 400 W | 1.27 N·m | 3,000 rpm | 10.6 A | — % | 100 mm |
13 main assembly steps. Each step lists its key equipment and instruments, their main suppliers, and the technical control points.
Thin low-loss electrical steel is punched in a progressive die into stator segments (or a full ring) and rotor laminations, interlocked or bonded in-die; rotor stacks are built with the specified skew steps.
Technical control points:
Moulded insulation end plates or overmoulded segment insulation are fitted and slot liners inserted, giving the creepage and clearance needed for 220 V mains-fed drives.
Technical control points:
Segmented stators are wound tooth by tooth on linear / flyer winders for high slot fill, then joined into a ring; one-piece stators are needle-wound. Coils follow the phase sequence for a balanced 3-phase winding.
Technical control points:
Coil ends are joined by fusing or soldering to a busbar ring or terminal board, then the power leads (U/V/W/PE) and brake leads are attached.
Technical control points:
100% electrical test before impregnation to catch turn shorts, wrong connections and insulation faults early.
Technical control points:
Vacuum-pressure or trickle impregnation followed by oven curing; some designs instead pot the stator in thermally conductive epoxy after it is fitted in the housing.
Technical control points:
The housing is heated (typically 200–300 °C) and the stator inserted with a fixture, giving an interference fit for torque transmission and good heat flow to the housing.
Technical control points:
The rotor core is pressed onto the shaft. Low-inertia rotors carry surface arc magnets bonded in skewed steps (often with a sleeve or banding); medium-inertia rotors have magnets inserted into core pockets and fixed with adhesive.
Technical control points:
Rotors are magnetized with a multi-pole fixture (or pre-magnetized magnets are inserted), followed by a surface-field scan of every pole.
Technical control points:
Measure and correct unbalance in two planes; servo rotors run at up to 6,000 rpm and need a tight grade for smooth motion at both low and high speed.
Technical control points:
Press-fit the bearings, insert the rotor into the stator, fit the flange and rear cover with O-rings, mount the holding brake and set its air gap, then press in the shaft oil seal and fit the sealed connectors.
Technical control points:
The encoder disc or magnet is fixed to the shaft and the read head mounted on the rear cover. The motor is locked with a fixed DC vector (or back-driven) and the electrical zero offset is written into the encoder memory together with the motor parameters.
Technical control points:
Every motor gets 100% electrical-safety, back-EMF, cogging, brake and sealing checks; load characteristics are sampled per batch with the matching drive.
Technical control points:
Suppliers are representative examples (international / mainland China), not an exhaustive or endorsed list.
Progressive stamping and in-die interlocking of stator and rotor laminations.
Selection criteria: Tonnage 60–200 t, 200–800 spm, bottom-dead-centre accuracy.
Used in: 1. Lamination stamping & stacking
Equipment page →Forms and interlocks laminations; determines core accuracy and burr.
Selection criteria: Number of stations, regrind interval, stack-height control method.
Used in: 1. Lamination stamping & stacking
Equipment page →Verifies dimensions, geometry and runout.
Selection criteria: Measurement uncertainty, probing system.
Used in: 1. Lamination stamping & stacking, 11. Final assembly (bearings, brake, oil seal)
Equipment page →Inserts slot-liner insulation into stator slots.
Selection criteria: Slot geometry range, cycle time, paper forming method.
Used in: 2. Stator insulation
Equipment page →Moulds insulation bobbins from PA66+GF.
Selection criteria: Shot accuracy, mould temperature control, resin drying.
Used in: 2. Stator insulation
Equipment page →Winds concentrated coils on inner-rotor stators.
Selection criteria: Spindles, wire-diameter range, tension control, layering accuracy.
Used in: 3. Winding
Equipment page →Joins enamelled wire to terminals without pre-stripping.
Selection criteria: Closed-loop control of current, force and time; joint monitoring.
Used in: 4. Phase connection & lead termination
Equipment page →Solders winding ends to lead wires or a terminal PCB; solderable enamel is stripped by the solder heat.
Selection criteria: Tip temperature stability, solder-wire feed, positioning repeatability, fume extraction.
Used in: 4. Phase connection & lead termination
Equipment page →Winding resistance, turn-to-turn insulation, hipot and insulation resistance.
Selection criteria: Surge voltage, waveform-comparison algorithm, test cycle time.
Used in: 5. Stator in-process test
Equipment page →Impregnates windings with varnish and cures it for insulation, heat transfer and vibration resistance.
Selection criteria: Vacuum level, heating method (current or oven), temperature profile.
Used in: 6. Impregnation & curing
Equipment page →Rotor-to-shaft and bearing press-fits with force–displacement monitoring.
Selection criteria: Force / displacement resolution, curve evaluation windows.
Used in: 7. Stator shrink-fit into housing, 8. Rotor assembly, 11. Final assembly (bearings, brake, oil seal)
Equipment page →End-of-line electrical safety tests.
Selection criteria: Output voltage, leakage-current resolution.
Used in: 7. Stator shrink-fit into housing, 13. End-of-line test
Equipment page →Applies adhesive for bonding rotor magnets.
Selection criteria: Shot-volume accuracy, 1K / 2K adhesive capability.
Used in: 8. Rotor assembly
Equipment page →Multi-pole magnetizing of rotor magnets, followed by surface-field measurement.
Selection criteria: Stored energy, peak current, fixture pole count and cooling.
Used in: 9. Magnetizing
Equipment page →Measures and corrects rotor unbalance (material removal or addition).
Selection criteria: Minimum achievable residual unbalance, balance grade (e.g. G2.5 / G6.3).
Used in: 10. Rotor balancing
Equipment page →No-load, load, T–N curve, efficiency, back-EMF and Hall-phase testing.
Selection criteria: Torque range and accuracy, speed range, data acquisition.
Used in: 12. Encoder mounting & commutation alignment, 13. End-of-line test
Equipment page →Checks assembled boards for shorts, opens and component values (ICT), programs the firmware, and tests the board's functions under power (FCT).
Selection criteria: Bed-of-nails fixture design, test coverage, programming interface, cycle time, data logging and traceability.
Used in: 12. Encoder mounting & commutation alignment
Equipment page →Main raw materials, purchased components and auxiliary materials. ★ marks items critical to performance or cost. Quantities are typical and vary by model.
| Part | Class | Material | Key specification | Qty | Supply chain / regions | Representative suppliers | Process | Tests |
|---|---|---|---|---|---|---|---|---|
| ★Stator / rotor core | Raw material | Non-oriented Electrical Steel | 35W300 / 35W360 or 50W470, low-loss | Per stack height | Mills are outside the Pearl River Delta (Baosteel, Shougang, Ansteel); Pearl River Delta buyers get slit coil from mill service centres and steel distributors in Foshan (Lecong) and Dongguan, or buy finished cores from stamping houses. Ask for the mill certificate with every coil. | WcanFoshan, HongwangFoshan, Fulwealth SteelDongguan+3 more → | Process → | View → |
| ★Winding | Raw material | Enamelled Copper Wire | Polyesterimide / polyamide-imide overcoat, class 180–200; inverter-duty grade for 220 V types | ≈ 0.2–1.2 kg | The Pearl River Delta has its own enamelled-wire makers in Zhuhai, Foshan, Jiangmen and Huizhou, alongside the big Anhui and Jiangsu producers. Local supply shortens lead time; still audit the thermal class and in-line test records per spool. | RonsenZhuhai, Jingda GuangdongFoshan, Suntek WireJiangmen+2 more → | Process → | View → |
| ★Magnets | Raw material | Sintered NdFeB Magnet | N42SH / N45SH or 38UH (150–180 °C), arc or rectangular, Ni or epoxy coated | 8–10 poles × skew steps | Sintered blocks come mainly from Ningbo, Baotou and Ganzhou; Dongguan, Shenzhen and Jiangmen host magnet makers and finishing plants that cut, grind, coat and magnetise to drawing. Specify grade, coating and Hcj at temperature, and ask which plant sinters the block. | Dawa MagnetDongguan, Jiada MagnetDongguan, Courage MagnetDongguan+6 more → | Process → | View → |
| Shaft | Raw material | Motor Shaft | C45 or 40Cr steel, ground, h6 extension with keyway | 1 | Dongguan is the Pearl River Delta centre for precision turned and ground shafts, with many CNC-turning and centreless-grinding shops serving the local motor industry. Check the h6 bearing-seat grinding capability and run-out inspection, not just turning. | Sanfeng ShaftsDongguan, LongmingDongguan, DayueDongguan | Process → | View → |
| ★Bearings | Purchased component | Deep-groove Ball Bearing | 6002 / 6203 / 6204 class, 2RS or ZZ, C3, high-speed low-noise grease | 2 | Bearing factories are mostly outside the Pearl River Delta (Zhejiang, Liaoning, Henan, Japan); the Pearl River Delta has brand sales offices in Guangzhou and Shenzhen and local makers of miniature bearings in Dongguan and Shenzhen. Buy branded bearings only through authorised channels to avoid counterfeits. | NSKGuangzhou, Fitrun BearingDongguan, Kentie BearingDongguan+6 more → | Process → | View → |
| Housing | Raw material | Aluminium Extruded Housing | 6063-T5 extrusion or die-cast aluminium, anodized or painted | 1 | Foshan (Nanhai, Dali) is China's largest aluminium-extrusion cluster, with more in Zhaoqing and Jiangmen; most extruded motor housings in South China are made there. Machining of the bore and spigot is often done by a second shop — agree who owns concentricity. | Honstar AluminumFoshan, Guoyao AluminiumZhaoqing, Kam KiuJiangmen | Process → | View → |
| Flange & rear cover | Raw material | Die-cast Aluminium End Cap | ADC12, finish-machined spigot and bearing seats | 2 | Foshan, Zhuhai and Dongguan have many high-pressure die-casters, from listed auto-parts groups to small motor-cap shops. Ask for X-ray porosity checks at the bearing seat and whether machining is done in-house. | JinjuqiweiFoshan, WencanFoshan, KingrunZhuhai+1 more → | Process → | View → |
| ★Absolute encoder | Bought-in part | — | 23-bit optical or magnetic, single-turn / multi-turn, serial protocol; code disc / magnet plus read-head PCBA | 1 | — | — | — | — |
| ★Holding brake (optional) | Bought-in part | — | 24 V DC spring-applied, power-off; holding torque ≥ rated motor torque | 1 | — | — | — | — |
| Insulation end plates & slot liner | Auxiliary material | Insulation Bobbin & Slot Liner | PA66+GF or PBT, UL94 V-0; slot liner NMN / DMD, class F | 1 set | Shenzhen and Huizhou have makers of insulation films, sleeving and moulded bobbins; slot liners (DMD, NMN, PET film) are also stocked by Dongguan distributors. Confirm the thermal class matches the insulation system and keep UL file numbers on record. | FuweiHuizhou, WoerShenzhen, JDDShenzhen | Process → | View → |
| Impregnating varnish / potting | Auxiliary material | Impregnating Varnish | Polyesterimide or epoxy, class F / H; or thermally conductive epoxy potting | Per pick-up | International varnish makers run Pearl River Delta offices and blending sites (Zhuhai), and Foshan and Zhuhai have domestic insulating-resin producers. Choose varnish and process together — the supplier's process support matters as much as the product. | ELANTASZhuhai, DRDFoshan, ChangxianZhuhai+1 more → | — | View → |
| Power, brake & encoder cables / connectors | Purchased component | Lead Wires & Connectors | Shielded flexible cables; M17 / M23 circular or sealed rectangular connectors rated IP65/67 | 1 set | Shenzhen and Dongguan are a major cluster for wire, harness and connector makers, including offices of international connector brands. Ask for crimp-force monitoring and pull-test records on terminated leads. | MolexShenzhen, WoerShenzhen, XSD CableDongguan+2 more → | Process → | View → |
| Magnet adhesive | Auxiliary material | Magnet Bonding Adhesive | Structural epoxy / acrylic, rated ≥ 150 °C | Small amount | Huizhou, Dongguan and Shenzhen have domestic structural-adhesive makers that supply motor magnet bonding, next to local offices of international brands. Ask for shear strength at operating temperature and run a trial on your own rotor. | KafuterHuizhou, MaxAdhesiveDongguan, YaonengShenzhen+2 more → | — | View → |
| ★Oil seal & O-rings | Bought-in part | — | NBR or FKM lip seal on the shaft; NBR O-rings at flange and rear cover | 1 set | — | — | — | — |
| Fasteners & small parts | Auxiliary material | Fasteners & Small Parts | Screws, keys, wave washers, circlips, earth terminal; stainless or zinc plated | 1 set | Dongguan and Shenzhen have many fastener makers and specialists in retaining rings and wave washers for small motors, so standard parts no longer have to come from Wenzhou or Ningbo. Check plating and hardness certificates per lot. | JinyiDongguan, LiangguDongguan, Lock TechnologyShenzhen+3 more → | Process → | View → |
How each key raw material and purchased component is made: process steps, the equipment and instruments used at each step with their main suppliers, and the technical control points. Click a material to expand.
Steelmaking & vacuum degassing → Hot rolling → Pickling & cold rolling → Continuous annealing → Insulation coating → Testing & slitting
Hot metal is refined in a converter, then RH-degassed to ultra-low carbon; silicon and aluminium are added to the target grade.
Technical control points:
Slabs are reheated and rolled into hot-rolled coils of about 2 mm.
Technical control points:
Scale is removed and the strip is cold-rolled to final gauge (0.50 / 0.35 mm).
Technical control points:
Recrystallization annealing in a protective atmosphere grows grains to the size that minimises core loss.
Technical control points:
A thin inorganic / organic insulation coating is applied and cured to limit interlaminar eddy currents and aid punchability.
Technical control points:
Magnetic properties are tested per coil, then coils are slit to the stamping width.
Technical control points:
Rod drawing → In-line annealing → Enamelling & curing → Lubrication, in-line testing & spooling
8 mm oxygen-free copper rod is drawn through successive diamond dies to the target diameter.
Technical control points:
Resistance annealing restores ductility after drawing.
Technical control points:
Base coat (polyesterimide) and overcoat (polyamide-imide) are applied in many thin passes, each cured in the oven.
Technical control points:
A surface lubricant is applied for winding, diameter and film faults are tested continuously, and wire is spooled.
Technical control points:
Melting & strip casting → Hydrogen decrepitation → Jet milling → Field orientation & pressing → Cold isostatic pressing → Sintering & ageing → Machining → Surface coating → Final inspection
Nd/Pr, Dy/Tb, Fe, B and additives are vacuum-induction melted and cast onto a water-cooled wheel into thin flakes.
Technical control points:
Flakes absorb hydrogen and crack along grain boundaries into coarse powder, followed by dehydrogenation.
Technical control points:
Coarse powder is milled in nitrogen to fine single-crystal particles.
Technical control points:
Powder is aligned in a strong magnetic field and pressed into blocks inside a protective glove box.
Technical control points:
Sealed green blocks are pressed isostatically to raise and even out density.
Technical control points:
Blocks are vacuum-sintered at about 1,050–1,100 °C, then aged in one or two stages to develop coercivity.
Technical control points:
Blocks are sliced, ground or wire-cut into arc segments, then chamfered and cleaned.
Technical control points:
Ni-Cu-Ni electroplating, zinc or epoxy coating protects the magnet from corrosion.
Technical control points:
Magnetic properties, dimensions and appearance are checked per lot.
Technical control points:
Bar cutting → CNC turning & keyway / D-cut → Heat treatment → Cylindrical grinding → Cleaning, rust protection & inspection
Cold-drawn or ground bar stock (SUS420J2 / C45) is cut to length.
Technical control points:
Shoulders, grooves and the shaft extension are turned; the keyway or D-cut is milled.
Technical control points:
Quench and temper (or induction hardening of bearing seats) for strength and wear resistance.
Technical control points:
Bearing seats and the shaft extension are ground to h6 tolerance.
Technical control points:
Parts are cleaned, rust-protected and inspected before packing.
Technical control points:
Ring forging & turning → Heat treatment → Grinding → Superfinishing → Cleaning, assembly, greasing & sealing → Vibration & noise test
GCr15 (52100) bearing steel is forged or turned into ring blanks.
Technical control points:
Through-hardening and tempering to about HRC 60–64.
Technical control points:
Faces, outer diameter, bore and raceways are ground.
Technical control points:
Raceways are superfinished for low roughness and low noise.
Technical control points:
Rings and balls are cleaned, matched for clearance, assembled with the cage, greased and shielded.
Technical control points:
Every bearing is spun and its vibration measured to classify the grade.
Technical control points:
Billet heating & extrusion → Stretching, cutting & ageing → CNC machining → Anodizing
6063 billets are heated and extruded through a die into the square housing profile, quenched at the press.
Technical control points:
Profiles are stretched straight, cut to length and artificially aged to T5.
Technical control points:
Spigot, bore, mounting holes and slots are machined.
Technical control points:
Parts are anodized (and optionally dyed) for corrosion protection and appearance.
Technical control points:
Melting & degassing → High-pressure die casting → Trimming & porosity inspection → CNC machining
ADC12 ingot is melted and degassed to reduce hydrogen porosity.
Technical control points:
Molten alloy is injected into the steel die at high speed and pressure.
Technical control points:
Gates and overflows are trimmed; castings are sampled by X-ray for porosity.
Technical control points:
Bearing seat, spigot and mounting faces are finish-machined.
Technical control points:
Resin drying → Injection moulding → Inspection
PA66+GF pellets are dried before moulding.
Technical control points:
Bobbins (end plates) are moulded, optionally with insert-moulded terminals.
Technical control points:
Dimensions, appearance and flammability conformance are checked.
Technical control points:
Cut, strip & crimp → Crimp verification → Housing insertion & continuity test
Wires are cut and stripped, and terminals crimped automatically.
Technical control points:
Cross-sections and pull tests verify each setup and lot.
Technical control points:
Terminals are inserted into connector housings and the harness is continuity-tested.
Technical control points:
Cold heading & thread rolling → Heat treatment & surface treatment → Optical sorting
Wire is cold-formed into screw blanks and threads are rolled.
Technical control points:
Parts are hardened as required, then zinc-plated or passivated.
Technical control points:
100% sorting removes dimensional and visual defects.
Technical control points:
Materials without a process here (bought-in chemicals, chips and some purchased components) are covered by incoming inspection and approval tests only.
Material-level tests are used for incoming inspection and supplier approval (PPAP / sample approval); motor-level tests for product validation (DV / PV). Conditions and criteria depend on the application and customer specification.
Applies to: Stator / rotor core
Applies to: Winding
Applies to: Magnets
Applies to: Shaft
Applies to: Bearings
Applies to: Housing
Applies to: Flange & rear cover
Applies to: Insulation end plates & slot liner
Applies to: Impregnating varnish / potting
Applies to: Power, brake & encoder cables / connectors
Applies to: Magnet adhesive
Applies to: Fasteners & small parts
| Test | Standard / condition |
|---|---|
| High-temperature operation and low-temperature start | IEC 60068-2-1 / -2-2 |
| Temperature cycling / thermal shock | IEC 60068-2-14 |
| Damp heat, steady state (e.g. 85 °C / 85% RH) | IEC 60068-2-78 |
| Salt spray | IEC 60068-2-11 |
| Sinusoidal / random vibration | IEC 60068-2-6 / -2-64 |
| Mechanical shock | IEC 60068-2-27 |
| Temperature-rise test | IEC 60034-1 |
| IP protection rating | IEC 60529 |
| Hipot and insulation resistance | IEC 60034-1 |
| Locked rotor and overload | Per customer specification |
| Endurance test (continuous rated load) | Per customer specification, typically 3,000–20,000 h |
| Noise and vibration | ISO 1680, IEC 60034-14 |
Motor for high-voltage drives: Covers motors sold in low-voltage and high-voltage versions. Versions driven above 75 V DC / 50 V AC (e.g. from 220 V AC drives) fall under low-voltage-directive safety rules and need reinforced insulation and hipot evidence.
Listed alphabetically, not in order of preference. Confirm accreditation scope with each body.
Cost analysis, supplier sourcing and audits, production-line planning and equipment selection, and export certification planning — consulting by a senior motor engineer.
Discuss on WhatsApp