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.
![Insulation Paper and Hairpin Position]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.100.75.0,75,600,525.file/03-e-motor-application-line-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.360.270.0,75,600,525.file/03-e-motor-application-line-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.600.450.0,75,600,525.file/03-e-motor-application-line-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.600.450.0,75,600,525.file/03-e-motor-application-line-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.600.450.0,75,600,525.file/03-e-motor-application-line-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.600.450.0,75,600,525.file/03-e-motor-application-line-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/03-e-motor-application-line-600px.jpg/_jcr_content/renditions/original.image_file.600.450.0,75,600,525.file/03-e-motor-application-line-600px.jpg"} "Insulation Paper and Hairpin Position")
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]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.100.56.0,131,600,469.file/05-assembly-inspection-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.360.203.0,131,600,469.file/05-assembly-inspection-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.600.338.0,131,600,469.file/05-assembly-inspection-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.600.338.0,131,600,469.file/05-assembly-inspection-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.600.338.0,131,600,469.file/05-assembly-inspection-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.600.338.0,131,600,469.file/05-assembly-inspection-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/05-assembly-inspection-600px.jpg/_jcr_content/renditions/original.image_file.600.338.0,131,600,469.file/05-assembly-inspection-600px.jpg"} "Assembly Volume Inspection")
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.
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original.image_file.100.100.file/10-emot-sw-mesh-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original.image_file.360.360.file/10-emot-sw-mesh-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original./10-emot-sw-mesh-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original./10-emot-sw-mesh-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original./10-emot-sw-mesh-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original./10-emot-sw-mesh-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/10-emot-sw-mesh-600px.jpg/_jcr_content/renditions/original./10-emot-sw-mesh-600px.jpg"})
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.
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original.image_file.100.100.file/12-zeiss-emotor-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original.image_file.360.360.file/12-zeiss-emotor-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original./12-zeiss-emotor-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original./12-zeiss-emotor-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original./12-zeiss-emotor-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original./12-zeiss-emotor-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/12-zeiss-emotor-600px.jpg/_jcr_content/renditions/original./12-zeiss-emotor-600px.jpg"})
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.
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original.image_file.100.100.file/13-emotor-software-teaser-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original.image_file.360.360.file/13-emotor-software-teaser-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original./13-emotor-software-teaser-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original./13-emotor-software-teaser-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original./13-emotor-software-teaser-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original./13-emotor-software-teaser-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/13-emotor-software-teaser-600px.jpg/_jcr_content/renditions/original./13-emotor-software-teaser-600px.jpg"})
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.
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original.image_file.100.100.file/15-e-motors-software-600px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original.image_file.360.360.file/15-e-motors-software-600px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original./15-e-motors-software-600px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original./15-e-motors-software-600px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original./15-e-motors-software-600px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original./15-e-motors-software-600px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/15-e-motors-software-600px.jpg/_jcr_content/renditions/original./15-e-motors-software-600px.jpg"})
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.
![Quality Assurance for Stators]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.100.33.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.360.120.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.768.256.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.1024.341.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.1280.427.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.1440.480.5,0,1921,639.file/header-motor-stator-1920x640px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/header-motor-stator-1920x640px.jpg/_jcr_content/renditions/original.image_file.1916.639.5,0,1921,639.file/header-motor-stator-1920x640px.jpg"} "Quality Assurance for Stators")
![Stator installation]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.100.75.2,229,719,767.file/07-application-image-768.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.360.270.2,229,719,767.file/07-application-image-768.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.717.538.2,229,719,767.file/07-application-image-768.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.717.538.2,229,719,767.file/07-application-image-768.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.717.538.2,229,719,767.file/07-application-image-768.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.717.538.2,229,719,767.file/07-application-image-768.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/07-application-image-768.jpg/_jcr_content/renditions/original.image_file.717.538.2,229,719,767.file/07-application-image-768.jpg"} "Stator installation")
![Identification of pores and defects]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original.image_file.100.100.file/08-defection-stator_768x768px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original.image_file.360.360.file/08-defection-stator_768x768px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original./08-defection-stator_768x768px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original./08-defection-stator_768x768px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original./08-defection-stator_768x768px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original./08-defection-stator_768x768px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/08-defection-stator_768x768px.jpg/_jcr_content/renditions/original./08-defection-stator_768x768px.jpg"} "Identification of pores and defects")
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.100.50.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.360.180.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.768.384.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1024.512.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1280.640.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1440.720.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1920.960.0,60,1920,1020.file/09-emot_scan_02_1920x1080px.jpg"})
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.100.100.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.360.360.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.768.768.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1024.1024.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1080.1080.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1080.1080.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/09-emot_scan_02_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1080.1080.840,0,1920,1080.file/09-emot_scan_02_1920x1080px.jpg"})
![]({"xsmall":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.100.56.file/17-vid-measurement-stator-preview_1920x1080px.jpg","small":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.360.203.file/17-vid-measurement-stator-preview_1920x1080px.jpg","medium":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.768.432.file/17-vid-measurement-stator-preview_1920x1080px.jpg","large":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1024.576.file/17-vid-measurement-stator-preview_1920x1080px.jpg","xlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1280.720.file/17-vid-measurement-stator-preview_1920x1080px.jpg","xxlarge":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original.image_file.1440.810.file/17-vid-measurement-stator-preview_1920x1080px.jpg","max":"https://www.zeiss.nl/content/dam/iqs/r/industries/automotive/nev/e-motor/stators/17-vid-measurement-stator-preview_1920x1080px.jpg/_jcr_content/renditions/original./17-vid-measurement-stator-preview_1920x1080px.jpg"})
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