Quality Assurance
for High-Performance E‑Motors
Reliable components through inspection and quality data
E-motor quality management in production
Highest accuracy for automated processes
Many of the components in compact high-performance electric motors are produced in automated processes. They require checks at every stage of production – though the requirements may vary, precision is a constant need. E-motor performance depends on ensuring proper positioning, accurate dimensions, and high-quality weld seams.
ZEISS excels when it comes to these precision assemblies, which require micrometer-level accuracy and a range of technologies including automated and contact-free solutions.
Full coverage of e-motor applications
Electric motors are the true powerhouses in electric vehicles, combining high speed and enormous torque while being light and compact. In order to achieve maximum performance with little wear, all components must interlock precisely for perfect interaction. Inspecting the hairpins and sheet stacks, checking weld seams on the stators, measuring the rotors and shafts – you can do it all with the ZEISS portfolio. Click the links below to explore our dedicated quality assurance solutions for electric motor applications.Hairpins
Inspection of dimensions and positions
Hairpins consist of a bent rectangular copper wire and are coated with an insulating layer. Since they are highly susceptible to deformation and their ends are difficult to weld, it is necessary to inspect the dimensions and positions of hairpins during the stator assembly process.
Sheet stacks
Inspection of geometry and surface
Sheet stacks comprise numerous 2D sheets less than 1 mm thick. 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. Micrometer-range tolerances mean the sheets must be flat and burr-free.
Stators
Defect inspection and digitization
Among all e-motor components, the stator offers the greatest potential for improving performance, power, and efficiency. Given new raw materials and innovative manufacturing technologies, quality assurance is required across all stator production steps to guarantee e-motor safety, reliability, and performance.
Rotors and shafts
Inspection of shape and location
Due to the high performance and speed of the e-motor, the rotor must meet very tight shape and location tolerances that require inspection. The air gap between the rotor and the stator bore is one of the main parameters defining the safety, reliability, and efficiency of the e-motor.
ZEISS eMobility solutions at every manufacturing step
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Extra insights into quality assurance for e-motors
“That’s why we have to perform constant checks from incoming goods to the fully assembled part: What is the bending behavior of the wire, does the geometry fit, is the paper insulation layer positioned between the hairpins and the sheet metal package, do the welds fit?”