The transition to e-Mobility is a major technological change, for both car users and manufacturers. For the latter, electric motors require new production lines and new quality control systems.
For Marposs, electric mobility has been the driving force behind the introduction of new measurement technologies necessary to meet the latest needs of the automotive industry. Traditional product lines, which are still applied regularly, are now complemented by solutions using optical technology dedicated to the components of the electric drive unit.
Today, optical gauges are the preferred quality control solution for electric vehicle (EV) manufacturers and their component suppliers. Automakers are accelerating their development activities to enter the market as quickly as possible with various solutions. As a result, the distance between research and development and a vehicle’s production launch is shrinking, making it critical to control components in the phases where they are continuously revised and updated. The flexibility of optical gauges is a crucial asset, as they can measure components of different shapes and sizes with very short cycle times.
Optical inspections are based on the image acquisition of the component to be inspected. Software algorithms automatically analyze the images, combine them and reconstruct the component geometry. The next steps are feature measurement and quality control.
Marposs has concentrated on developing new, or enhancing existing, dimensional and inspection solutions by applying transversal competencies on various technologies. For example, an existing optical precision measurement solution, initially developed for the quality control of traditional automotive components, has been enriched with new sensors and software functions to now measure EV components, such as rotors.
The application capability of optical gauges is experiencing unprecedented potential as it exploits the synergy between the evolution of image sensors and software algorithms. The evolution of optical technology has been very fast: Just a few years ago, precision systems were based solely on linear image sensors. Today, the technology also provides two-dimensional image sensors that allow the capture of the component profile to be measured in one pass, thus improving the performance and speed of inspection cycles.
The evolution of sensor technology from 2D to 3D, made possible by optical laser triangulation sensors, has allowed the 3D position of each point on the visible surface of the part to be reconstructed with a point cloud.
To generate a point cloud of the workpiece, the part is quickly rotated 360° while the laser heads each acquire spatial data that is then combined into a single 3D reconstruction and graphical representation made possible through the software. Not only does this enable accurate dimensional measurement, but also allows line operators to perform qualitative checks on the shape and geometry of the weld meniscus or on the presence of tears in the protruding part of the insulation.
Optical measurement using 3D sensors is particularly suitable for performing more complex measurement and control. For example, these 3D technologies are well suited for the dimensional control and inspection of electromobility components such as an assembled stator, before or after the twisting operations and subsequent welding of the ends of the hairpins.
No matter the change in power transmission for vehicles, reducing time to market, controlling costs and quality will always remain primary demands and, to-date, 3D optical inspection is designed to address these challenges.
Connect With Us