ZEISS ScanBox 4105 for eMotors

The virtual measuring room (VMR) is opened in ZEISS INSPECT. It contains a functional image of the real ZEISS ScanBox 4105 for eMotors as well as the robot programming including the kinematics of the robot paths. Smart Teach functions are used to define the sensor positions to be tested, which are then automatically evaluated and optimized by the software. All positions contained in the measurement plan can then be traversed and compared with previously imported CAD data or a reference model previously created offline.

Once the digital geometric twin has been created, the actual data can be compared to the nominal data from the CAD model. For this purpose, the two data sets are aligned with each other, e.g. via the inner cylinder of the sheet metal package, a face, notch or a connecting hole. A comparison of surfaces can be used to check various quality criteria. While the inspection of a stator includes checking for cracks, deformations of the winding cage or the connection points, deflections, displacements, and the roundness of the inner cylinder, the focus of the hairpin inspection is on features such as deformations at the hairpin ends or the bending and folding process.

Using automatic trend analysis, deviations from the ideal model can be identified at an early stage. Changes in previous production steps are quickly detected by continuous measurements. Necessary adjustments can be derived from this and implemented in previous production steps.

The stator and the rotor in the electric motor must be precisely aligned with each other. This can be simulated and checked in advance by using digital assembly. It aims at evaluating the fitting accuracy of the components.