Manufacturing overview · Typical process
IEC frames 80–160 · 380–415 V 50 Hz / 460 V 60 Hz · 0.75–15 kW · 4-pole
The workhorse of pumps, fans, compressors and conveyors, built to IEC dimensions and IE3 efficiency (IEC 60034-30-1). A 36-slot stator with a distributed lap winding in enamelled copper, a die-cast aluminium squirrel-cage rotor, deep-groove ball bearings and a self-ventilated (IC 411) cast-iron or aluminium frame in foot (B3) or flange (B5) mounting. Single-phase capacitor motors (YY capacitor-run, YL capacitor-start-and-run) use the same construction, with a main plus auxiliary winding and a run and/or start capacitor in the terminal box.
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Click a model for full specifications and curves.
| Model | Voltage | Rated power | Rated torque | Rated speed | Current | Rated efficiency | Body length |
|---|---|---|---|---|---|---|---|
| YE3-80M2-4 | 380 V | 750 W | 5.15 N·m | 1,390 rpm | 1.84 A | 82.5 % | 325 mm |
| YE3-90L-4 | 380 V | 1.5 kW | 10.3 N·m | 1,390 rpm | 3.47 A | 85.3 % | 385 mm |
| YE3-100L1-4 | 380 V | 2.2 kW | 14.9 N·m | 1,410 rpm | 4.76 A | 86.7 % | 445 mm |
| YE3-112M-4 | 380 V | 4 kW | 26.6 N·m | 1,435 rpm | 8.37 A | 88.6 % | 480 mm |
| YE3-132M-4 | 380 V | 7.5 kW | 49.7 N·m | 1,440 rpm | 15 A | 90.4 % | 520 mm |
| YE3-100L1-4 | 380 V | 2.2 kW | 14.8 N·m | 1,420 rpm | 4.76 A | 86.7 % | 380 mm |
| YE3-160M-4 | 380 V | 11 kW | 71.9 N·m | 1,460 rpm | 21.5 A | 91.4 % | 615 mm |
| YY712-4 | 220 V | 370 W | 2.52 N·m | 1,400 rpm | 2.95 A | 62 % | 247 mm |
| YY802-4 | 220 V | 750 W | 5.12 N·m | 1,400 rpm | 5.45 A | 68 % | 286 mm |
| YL90S-4 | 220 V | 1.1 kW | 7.5 N·m | 1,400 rpm | 7.21 A | 73 % | 310 mm |
12 main assembly steps. Each step lists its key equipment and instruments, their main suppliers, and the technical control points.
Stator and rotor laminations are punched from the same electrical-steel coil in a progressive or compound die (rotor laminations come from the stator bore). Stator laminations are stacked to length under pressure and fixed by welding or cleats; rotor laminations are stacked on a skew mandrel ready for die-casting.
Technical control points:
The preheated rotor stack is clamped in the die and high-purity aluminium is injected to form the bars and both end rings in one shot. Melt cleanliness, hydrogen degassing and die temperature control porosity, which raises rotor resistance (lower efficiency) and can cause broken bars.
Technical control points:
The shaft is shrink-fitted or press-fitted into the cast rotor, then the rotor OD is finish-turned between centres to set the air gap; aluminium flash is removed from the end rings.
Technical control points:
Two-plane dynamic balancing with a half key in the shaft keyway (IEC 60034-14 half-key convention); correction by drilling or adding balance weights on the end rings.
Technical control points:
Class F slot liners (DMD or NMN) are formed with cuffs and inserted into each stator slot to insulate the winding from the core.
Technical control points:
Coil groups are wound on adjustable formers, then inserted into the slots by a coil inserter or by hand, together with slot wedges (top sticks). Phase insulation is placed between phases in the end windings; double-layer windings also get a layer separator in the slot.
Technical control points:
Coil ends are joined (crimped or brazed) and sleeved, lead wires attached, and thermal protectors (PTC / thermostat) embedded where specified. End windings are laced with polyester cord and pressed to final shape, clear of the frame and rotor.
Technical control points:
100% electrical test before impregnation, while winding faults can still be repaired.
Technical control points:
The stator is preheated and impregnated by VPI or dipping (often two dips), then oven-cured. Varnish fills slot voids and bonds the winding, raising dielectric strength, heat transfer and resistance to vibration and humidity.
Technical control points:
Cast-iron or aluminium frames are machined for the stator bore, spigots, feet or flange; end shields for bearing seats and spigots. Concentricity of stator bore, spigots and bearing seats sets air-gap uniformity.
Technical control points:
The stator is shrink- or press-fitted into the frame; bearings are fitted to the rotor; rotor and end shields are assembled, followed by fan, fan cover, terminal box, terminal block and seals. The motor is then painted and the nameplate fitted.
Technical control points:
Every motor receives routine tests per IEC 60034-1; efficiency is verified in type tests and periodic samples by the summation-of-losses method of IEC 60034-2-1, against the IE3 limits of IEC 60034-30-1.
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 & stator core 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 & stator core stacking
Equipment page →Verifies dimensions, geometry and runout.
Selection criteria: Measurement uncertainty, probing system.
Used in: 1. Lamination stamping & stator core stacking, 3. Rotor shaft fitting & turning, 10. Frame & end-shield machining
Equipment page →Melts the alloy and removes hydrogen to reduce porosity.
Selection criteria: Melt temperature, rotary degassing, density index.
Used in: 2. Rotor die-casting
Equipment page →Casts end caps from molten ADC12.
Selection criteria: Locking force, real-time shot control, vacuum assist.
Used in: 2. Rotor die-casting
Equipment page →Detects internal porosity and shrinkage in castings.
Selection criteria: Resolution, automatic defect recognition.
Used in: 2. Rotor die-casting
Equipment page →Rotor-to-shaft and bearing press-fits with force–displacement monitoring.
Selection criteria: Force / displacement resolution, curve evaluation windows.
Used in: 3. Rotor shaft fitting & turning, 11. Final assembly & painting
Equipment page →Turns shafts and machines bearing seats.
Selection criteria: Spindle accuracy, bar feeder, live tooling.
Used in: 3. Rotor shaft fitting & turning, 10. Frame & end-shield machining
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: 4. Rotor balancing
Equipment page →Inserts slot-liner insulation into stator slots.
Selection criteria: Slot geometry range, cycle time, paper forming method.
Used in: 5. Slot insulation, 6. Coil winding & insertion
Equipment page →Joins enamelled wire to terminals without pre-stripping.
Selection criteria: Closed-loop control of current, force and time; joint monitoring.
Used in: 7. Connection, lacing & forming
Equipment page →Winding resistance, turn-to-turn insulation, hipot and insulation resistance.
Selection criteria: Surge voltage, waveform-comparison algorithm, test cycle time.
Used in: 8. Stator in-process test, 12. Routine & efficiency 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: 9. Impregnation & curing
Equipment page →Mills spigots, holes and keyways on housings and end caps.
Selection criteria: Positioning accuracy, 4th axis, tool changer.
Used in: 10. Frame & end-shield machining
Equipment page →End-of-line electrical safety tests.
Selection criteria: Output voltage, leakage-current resolution.
Used in: 12. Routine & efficiency test
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. Routine & efficiency test
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 core | Raw material | Non-oriented Electrical Steel | 50W470 / 50W600 (IE3), 0.5 mm, C-5 / C-6 coating | Per core length | 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 → |
| Rotor core | Raw material | Non-oriented Electrical Steel | Same coil as the stator, punched from the stator bore | Per core length | 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 → |
| ★Stator winding | Raw material | Enamelled Copper Wire | Polyesterimide or PEI / PAI overcoat, class 180–200, grade 1–2 round wire, Ø0.5–1.3 mm, parallel strands | ≈ 2–15 kg (frames 80–160) | 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 → |
| ★Rotor cage (bars & end rings) | Bought-in part | — | Die-cast pure aluminium, ≥ 99.7% Al | Per rotor size | — | — | — | — |
| Shaft | Raw material | Motor Shaft | C45 steel, turned and ground; extension k6 / j6 with keyway per IEC 60072-1 | 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 | Deep-groove 6204 to 6309, 2Z / 2RS, C3 clearance, grease rated 120 °C or higher | 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 → |
| ★Frame | Raw material | Aluminium Extruded Housing | Grey cast iron HT200 / HT250, or aluminium alloy (frames 80–132); ribbed, B3 feet or B5 / B14 flange | 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 → |
| End shields | Raw material | Die-cast Aluminium End Cap | Cast iron HT200 or die-cast aluminium, machined bearing seats and spigots | 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 → |
| ★Slot, phase & wedge insulation | Auxiliary material | Insulation Bobbin & Slot Liner | DMD / NMN, class F (155 °C); slot wedges of laminate or DMD | 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 | Auxiliary material | Impregnating Varnish | Polyester / polyesterimide or solventless epoxy, class F / H | 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 → |
| Cooling fan & fan cover | Bought-in part | — | Fan in PP / PA or cast aluminium; fan cover in pressed sheet steel | 1 set | — | — | — | — |
| Terminal box, terminal block & leads | Purchased component | Lead Wires & Connectors | 6-terminal block with Y / Δ links, silicone or XLPE leads, cable glands | 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 → |
| ★Capacitors (YY / YL single-phase only) | Bought-in part | — | Run: metallised polypropylene film, 450 V AC; start (YL): AC electrolytic, 250–300 V AC, with centrifugal switch | 1–2 | — | — | — | — |
| Paint | Bought-in part | — | Alkyd or polyurethane enamel, RAL colour per order | Per surface area | — | — | — | — |
| Fasteners & small parts | Auxiliary material | Fasteners & Small Parts | Bolts, key, wave washer, circlips, oil seal / V-ring, gaskets, earth terminal, nameplate | 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:
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 core, Rotor core
Applies to: Stator winding
Applies to: Shaft
Applies to: Bearings
Applies to: Frame
Applies to: End shields
Applies to: Slot, phase & wedge insulation
Applies to: Impregnating varnish
Applies to: Terminal box, terminal block & leads
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.
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