ZEISS EMOBILITY SOLUTIONS

Quality Assurance for Sheet Stacks

Sheet inspection and stack positioning

Ensuring stack quality sheet by sheet

Tight tolerances and pristine surfaces

Single 2D sheets provide the foundation for constructing sheet stacks in rotors and stators. Sheet stacks comprise numerous sheets, each punched or laser cut from electrical steel sheets and with a thickness of less than 1 mm. Key quality aspects include the cross-section slot geometry for the hairpins, the permanent magnet slots, and the inner and outer diameter of the sheet stack assembly. Since tolerances are in the micrometer range, the sheets must be flat and burr-free to ensure proper e-motor performance.

Key quality challenges for sheet stacks

Single sheet inspection

Production of single sheets

Since the geometry of the 2D sheet defines the dimensions of the final stator and permanent magnet slots, it is very important to measure these dimensions quickly and with high accuracy. The sheet thickness and associated flexibility lead to measurement challenges.

ZEISS Optical Series

Geometrical inspection

Production of single sheets

ZEISS multisensor technology, such as 2D cameras and confocal light sensors, is used to measure the flatness of each individual sheet. Flatness and the absence of burrs are key factors for ensuring a sheet stack that is perfectly constructed and easy to assemble.

ZEISS CALYPSO software

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Assembly challenges

Sheet stack production

The positioning of the single sheets for laser welding has a major impact on the geometry of the stator and rotor slots, which are mated with the hairpins and the magnets. After welding, it is important to inspect the dimensions and positions of the slots as well as the height and diameter of the sheet stack. The contour features on the assembly are also important for the process of inserting the hairpins and magnets.
Assembly solutions

Sheet stack production

Multisensor ZEISS coordinate measuring machines can be combined with 2D cameras and white light confocal sensors for even more thorough inspection. They are capable of performing automated high-speed inspection of component pallets without any operator intervention.

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Quality Assurance for Sheet Stacks

Sheet inspection and stack positioning

Ensuring stack quality sheet by sheet