Quality Assurance for Stators

Quality Assurance for Stators

Defect inspection and 3D measurement

Tap into next-level e-motor performance with stators

Positioning, defect detection, and digitization

Among all components in the latest generation of electric motors, the stator offers the greatest potential for improving e-motor performance, power, and efficiency. Given the use of new raw materials and innovative manufacturing technologies, it is essential to perform quality assurance across all stator production steps in order to guarantee the safety, reliability, and performance of e-motors.

Key quality challenges for stators

Insulation Paper and Hairpin Position

Insulation paper and hairpin position

Dimensional metrology

During stator assembly, the insulation paper and hairpins are inserted into sheet stack slots and welded together. The power supply connection points are also welded. Multiple characteristics must be inspected to avoid stator short circuits. The highly flexible copper hairpins mean that flexible tactile and optical technologies are needed for accurate inspection of positions and dimensions – and a ZEISS multisensor coordinate measuring machine (CMM) is the ideal solution.

Assembly Volume Inspection

Assembly volume inspection

Analysis of installation space dimensions

If the external dimensions of the stator exceed the available installation space in the electric motor housing, then it will not be possible to assemble the e-motor. ZEISS coordinate measuring machines (CMMs) equipped with mass technology ensure automated switching between different sensor technologies. The combination of laser triangulation probes and tactile stylus systems enables full quality assurance for the preassembled stator.

  • Stator installation

    Weld seam inspection

    Stator installation

    When welding the hairpin ends, both lacquer residue at the stripped ends and fluctuating weld parameters can result in porosities in the weld seams. This can lead to reduced performance or even cause the total failure of the e-motor. It is therefore critical for e-motor performance that these weld seams are inspected for possible defects.

  • Identification of pores and defects

    Weld seam inspection

    Identification of pores and defects

    The non-destructive inspection of all weld seams for possible defects poses a particular challenge. Industrial computed tomography (CT) solutions such as ZEISS VoluMax 9 titan or ZEISS METROTOM can be used to non-destructively identify pores and defects inside hairpin weld seams. In this image, automated defect detection with AI support is performed on hairpins using ZEISS Automated Defect Detection (ZADD).

Efficient quality assurance in stator production

With ZEISS ScanBox for eMotors

ZEISS ScanBox for eMotors specializes in the inspection and digitization of hairpins and stators. From individual hairpins to multiple hairpins and even complete stators, this fully automated inspection is performed with great speed and precision. The captured 3D measurement data is then visualized and analyzed via powerful inspection software in the ZEISS Quality Suite.

Optical 3D measurement technology for eMobility

Fast, precise, and reproducible measuring results

Full surface digitization

ZEISS ScanBox for eMotors has been specifically developed to perform automated full-surface scanning and digitization of individual hairpins, multiple hairpins, and even complete stators.

Geometric digital twin

The software generates a full geometric digital twin using 3D coordinates distributed over a wide area. This enables quick and reproducible identification of deviations and defects in the component geometry by means of comparison with the CAD model.

Virtual measuring room

The virtual measuring room (VMR) is opened in ZEISS Quality Suite. In addition to a functional image of the real ZEISS ScanBox for eMotors, it also contains the robot programming including the kinematics of the robot paths.

Trend analysis

Automatic trend analysis enables the early identification of deviations from the ideal model. Continuous measurement ensures swift detection of changes resulting from previous production steps: Necessary adjustments can then be derived from this information and implemented in these earlier steps.

Extra insights into quality assurance for stators

  • Multiple measuring tasks handled by precision ZEISS technology
    Measurement of e-motor stator
  • Multiple measuring tasks handled by precision ZEISS technology
    Measurement of Stator Features
  • Multiple measuring tasks handled by precision ZEISS technology
    Measurement of E-Motor Winding Head

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