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Production Inspection System For Hairpins & Stators

The ScanBox for eMotors, recently launched by ZEISS, specializes in quick and accurate inspection and digitization of hairpins and stators. The automated system can inspect complete stators, including hairpins, as well as individual or multiple hairpins, with exceptional speed. The captured 3D measurement data is analyzed within ZEISS Quality Suite’s powerful inspection software.

Fast, Precise and Reproducible Measuring Results

Integrating seamlessly with the ScanBox for eMotors, the ZEISS ATOS Q sensor captures detailed quality information in a short amount of time. The non-contact fringe projection technology used by ATOS Q allows for the precise acquisition of measurement points, even for delicate structures. This information forms a dependable foundation for evaluation.

The ZEISS ScanBox for eMotors was designed specifically for automated, full-surface scanning of complete stators and single or multiple hairpins without any prior surface treatment. The software generates a complete geometrical digital twin using 3D coordinates distributed over a wide area, allowing for rapid and reproducible identification of component deviations and defects compared to the CAD model. The Kiosk Interface, a user-friendly software interface, allows for easy program and control of the ZEISS ScanBox for eMotors. Simply insert the component, select the measuring program, and press the start button.

The ZEISS ScanBox for eMotors is operated through the inspection software in the ZEISS Quality Suite, from data acquisition to inspection and reporting. The measurement workflow accommodates both simple and complex inspection tasks, from individual measurements to series production monitoring. The Kiosk Interface and virtual measurement room (VMR) execute measurement and inspection sequences through an intuitive user interface. Hairpin quality control analyses typically include form, angle, and position tolerances, as well as bending points, radii, and leg lengths.

Geometrical Digital Twin

After generating the digital geometrical twin, the actual data is compared with the nominal data from the CAD model. The two data sets are aligned by using a common feature such as the inner cylinder of the sheet metal package, a face, notch, or connecting hole. Various quality criteria are checked through a comparison of surfaces. For stator inspection, cracks, deformations of the winding cage or connection points, deflections, displacements, and the roundness of the inner cylinder are assessed. Hairpin inspection focuses on features such as deformations at the hairpin ends or the bending and folding process.

In the ZEISS Quality Suite, the virtual measuring room (VMR) provides a simulated environment for the ZEISS ScanBox for eMotors, complete with the robot programming and kinematics of robot paths. Smart Teach functions are utilized to specify the sensor positions to be tested, which the software automatically evaluates and optimizes. Once the measurement plan is established, all positions can be traversed and compared to previously imported CAD data or an offline reference model.

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