The challenge for K|Lens
A stator is the immovable part of an electric motor or generator. It is the counterpart to the rotor, the moving part. The hairpins in a stator are an essential component of modern electric motors, especially in applications such as electric vehicles. Their function is closely linked to the efficient generation of the magnetic field required for motor movement.
The quality of the welding of these hairpins has a direct influence on the electrical efficiency and thermal behavior of the motor. This makes the welding process a critical point in production. Both a qualitative evaluation of the welding (e.g. the shape of the weld spots) and a quantitative evaluation of the geometry of the welded pins are required.
Inspection methods
Traditional assessment by machine operators is subjective and can lead to inconsistencies. Moving the heavy stators for inspections is often difficult, time consuming and tiring. In addition, there is often a lack of comprehensive documentation of inspection results, making it difficult to trace defects.
Technical requirements
Capturing precise 3D topologies of complex structures, such as those found in welded hairpins, is challenging. High-quality imaging is required both for the creation of these 3D models and for qualitative analyses, but this is made very difficult by reflective surfaces and close contacts. The integration of the generated 3D and image data into existing IT systems, including the use of the customer's own AI, requires flexible interfaces.
The solution from K|Lens
Revolutionary Inspection: 3D Hairpin Weld Analysis with K|Lens Light Field Sensor
Our modern inspection systems use the patented K|Lens Light Field Sensor to generate images from different perspectives with just one shot. This data is used to create detailed 3D models of the hairpin welds. At the same time, they serve as the basis for the customer's own AI infrastructure. The different viewing angles are a decisive factor for the high accuracy of defect detection. The automated analysis reduces the time required for the inspection and improves the reliability of the results.
Enhancing Quality & Efficiency: AI-Powered Hairpin Weld Inspection
The main goal of hairpin analysis is to ensure high quality hairpin welds. This helps to improve the performance and reliability of electric motors and reduces production costs by avoiding rejects and rework. In addition, precise analysis prevents downtime during further processing of the stators.
Proven Solution
The K|Lens technology is used in several production lines in the automotive industry.
System used
Our weldAI system is an innovative 3D inspection system that has been specially developed for the demanding quality control of hairpin welds in electric motor production. It was supplied with the basic equipment for this application.
Specific design of the components / structure / extensions
Highly innovative sensor technology
Our Light Field Sensor HighRes delivers precise image data. The resolution and distance are selected such that a row of pins can be analyzed along the radius.
3D analysis
Precise 3D analysis is made possible by special calibration and depth calculation components. These components ensure an accurate and measurable 3D reconstruction of the hairpin, which is essential for defect detection.
APIs
The generated multi-view image data and the 3D models are integrated into the customer's IT environment via HALCON and C++ interfaces. The evaluation is carried out with the customer's own AI.
Customer Benefits and ROI
Cost savings and ROI
Reduction in process costs
Automated control is faster and more efficient than manual control by employees and requires fewer personnel. This significantly reduces process costs.
Reduction of rejects and rework
The early correct detection of defects through repeatable and objective processes reduces scrap and rework. This leads to significant cost savings.
Optimization of manufacturing processes
The detailed inspection data enables the optimization of manufacturing processes. This increases efficiency and reduces production costs.
Defense against warranty costs
The automatic creation of a digital twin of the hairpins enables follow-up inspection even after delivery, reducing the costs of traceability and warranties.
Improved quality control and accuracy
Objective and consistent quality control
Automated inspection reduces operator error and subjective judgment, resulting in objective and consistent quality control.
Precise defect detection
Advanced sensor technology and 3D analysis enable precise detection of defects that could not be achieved with conventional imaging methods.
Generation of 3D topology data of difficult structures
The system's ability to generate 3D topology data of complex structures, even with reflections and close contacts, allows for more comprehensive and accurate analysis.
Improved product quality
Comprehensive analysis and accurate defect detection help improve product quality, resulting in higher customer satisfaction.
Improved efficiency and productivity
Automated inline inspection
K|Lens relies on inline inspections in the customer's cycle time.
Real-time monitoring
The generated image data enables continuous monitoring of the inspection process. This enables a rapid response to potential problems and minimizes downtime.
Contact us
Let’s talk about your project
