The growing consumer demand for longer driving range in electric vehicles has prompted manufacturers to place higher demands on the precision manufacturing of motors. The forming shape of the hairpins in the standard motor stator body, the bending accuracy of the flat wire ends, and the consistency and assembly precision of the hairpin insertion have become crucial. How can manufacturers verify the critical dimensions of these stator components and shorten the measurement cycle?
The motor stator assembly is not a simple inspection component; rapid detection of component defects during the production process is an effective means to improve product quality and production yield.
● The flat wire ports of the motor have a hairpin design, requiring a welding process for connection. Poor welding can lead to weld voids, affecting motor performance. Traditional contact measurement requires a significant amount of time to inspect the dimensional characteristics of the welds, as manufacturers typically need to inspect more than 150 welds.
●The position and height of the insulation paper between the flat wire and the stator laminations are crucial to the insulation quality of the motor, making the inspection of the position of the flat wire ends essential. Insulation paper height is almost a two-dimensional measurement, requiring a small probe and a slow scanning speed to capture the edge data.
For this type of feature detection with high repeatability, the ZEISS CONTURA coordinate measuring machine is equipped with optical probes ZEISS LineScan and ZEISS ViScan, enabling faster measurements.
●ZEISS LineScan can quickly create weld point clouds for rapid extraction of height data for each weld. ZEISS LineScan does not require physical contact with each weld; instead, it uses laser triangulation to collect hundreds of data points per second, enabling rapid weld measurement.
● When used with a rotary table, the ZEISS ViScan easily measures the height of each insulating sheet, collecting overall data. This method is not only faster than contact measurements but also provides more data. When scanning with the ZEISS ViScan, the sensor quickly captures an image and extracts a line of data, approximately 30 to 70 points.
ZEISS ScanBox for eMotors enables non-contact, fully automated digitization of the motor stator's sensitive structure. With just a single setup, it can complete the full point cloud measurement of the entire stator, acquiring its three-dimensional data. During the scanning process, each image acquired by the probe contains up to 12 million data points, providing high data density for feature extraction and measurement of stator components.
