Citation: Parv, A.L.; Daicu, R.; Dragoi, M.V.; Rusu, M.; Oancea, G. A Method to Design Assembling Lines for Super Premium Efficiency Motors. Processes 2023, 11, 215. https:// doi.org/10.3390/pr11010215 Academic Editor: Antonino Recca Received: 19 December 2022 Revised: 5 January 2023 Accepted: 6 January 2023 Published: 9 January 2023 Copyright: © 2023 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). processes Article A Method to Design Assembling Lines for Super Premium Efficiency Motors Aurica Luminita Parv 1, * , Raluca Daicu 1 , Mircea Viorel Dragoi 1 , Marian Rusu 2 and Gheorghe Oancea 1, * 1 Department of Manufacturing Engineering, Transilvania University of Brasov, 500036 Brasov, Romania 2 Electroprecizia Electrical Motors, 505600 Sacele, Romania * Correspondence: luminita.parv@unitbv.ro (A.L.P.); gh.oancea@unitbv.ro (G.O.) Abstract: Producing highly efficient electric motors remains a challenge nowadays. Given that the legislation in the field requires the transition to the production of engines with increased efficiency, for manufacturing companies, switching from one generation of engines to another can be a difficult task. This paper analyzes ways to adapt the assembly of engines of the IE4 generation starting from the assembly lines of the engines of the previous generation, IE3. The analysis of the assembly process covers both the operator training part and the actual assembly part. Ten possible variants for the assembly line and specific decisional variables have been defined. The decision to choose the optimal assembly configuration was made using as management tools the matrix of consequences and utilities. The validation of the theoretical model of the assembly line was carried out through a case study built for two classes of electric motors, namely G90 and G180. For a total production of IE4 electric motors of 20,000 parts/month, the analyzed variants, respectively, the two sizes (G90 and G100) represent 35% (7000 parts/month) of the G90 size and 22% (4400 parts/month) the G100 size. The aim is to provide a new modular assembly concept, which depending on the orders, can use, as given in the conclusion of this article. Keywords: electrical motors; super premium efficiency; modular assembly concept; assembling line 1. Introduction Asynchronous electric motors play a major role in the current human civilization. The transformation of electrical energy into the rotary motion of a shaft is the basis of the operation of a multitude of machines and equipment [1–3]. As the main actuation element, the efficiency of converting electrical energy into mechanical energy is an ongoing concern. In this sense, efficiency standards have been developed [2,4]. The International Electrotechnical Commission (IEC) developed 5 efficiency standards, IE1÷IE5, but for now, the industry assimilates the IE4 standard [1,2,4]. In the activity of designing new types of engines, the following aspects are taken into account: • reduction of losses (in the stator winding, in the stator core, but also for slip losses in the rotor); • according to [5,6], solutions will be sought such as the copper windings will have a higher profile (deeper notches in the stator or rotor core), thinner (below 0.5 mm), and steel sheets will be used better for the core (Fe + C + Si alloy sheets obtained by more special laminations); • at the same time, the gap will be reduced, and the induced reaction (inherently increased by reducing the distance between the stator and the rotor) will be improved by specific methods (providing damping bars for rotors with visible poles or designing pole pieces for those with buried poles, or through other more innovative methods) [7]; • special attention will be paid to self-ventilation through redesign and simulation with specialized software [8]; Processes 2023, 11, 215. https://doi.org/10.3390/pr11010215 https://www.mdpi.com/journal/processes