weldAI is an innovative 3D inspection system that has been specially developed for the demanding quality control of hairpin welds in electric motor production.
weldAI - Inspection of hairpin welding for electrical vehicles
The importance of weldAI in electric motor production
weldAI ensures the product quality of critical hairpin welds in electric motors by providing AI-enabled imagery and 3D models for precise, automated inspection. This speeds up the production process and reduces manpower, leading to efficiency gains and cost savings. Through highly detailed images from different perspectives and precise 3D reconstructions, weldAI enables continuous improvement of production processes by allowing companies to identify sources of error and optimize processes. The system also offers flexibility and adaptability to different hairpin types and inspection requirements, enabling seamless integration into existing production lines.
The technology behind weldAI
weldAI utilizes the state-of-the-art and patented K|Lens Light Field Sensor to accurately capture 3D data from hairpin welds. This data can be analyzed to detect defects such as incomplete welds, incorrect geometries or damage. With weldAI, all data relating to a component can be archived to ensure complete traceability and documentation of the results. The connection to systems is made via a HALCON interface, which enables seamless integration into existing production processes and is considered the industry standard for image processing.
Important technical features
Optimized field of view
The field of view is large enough to capture a row of contacts over the radius. This enables the simultaneous inspection of several welding points and reduces the inspection time.
High depth of fieldThe depth of field of 12-15 mm also enables the analysis of lateral pin areas on the welded pin. This ensures a comprehensive inspection of the weld seam geometry.
Flexible working distanceThe working distance is approx. 70 mm, other distances (and corresponding working ranges) are possible.
Robot integrationThe system can be moved into the work area on a robot arm. This enables flexible integration into automated production lines.
Fast evaluationThe evaluation of a pin row (1 image) in 1 second is possible. A purely qualitative AI-based analysis can be performed much faster (<100 ms).
Connection to your systemsweldAI provides all required data via HALCON or C++ interfaces. This enables seamless integration into existing production processes. HALCON is an industry standard for image processing
Integration options / expansion options
Link to existing system landscape
weldAI can be seamlessly integrated into your existing system landscape to ensure smooth data exchange and efficient control. This includes connection to your production databases, quality management systems and other relevant systems.
Customized machine integrationWe perform customized machine integration to optimally adapt weldAI to your specific production machine. This includes customization of hardware, software and interfaces to ensure seamless integration into your production process.
Customized GUI for detailed analysisWe create a graphical user interface (GUI) customized to your needs for detailed analyses. This enables intuitive operation and comprehensive evaluation of the inspection results. The GUI can be customized to provide you with exactly the data and functions you need.
Adaptation to different hairpin typesweldAI can be flexibly adapted to different hairpin types to ensure comprehensive quality control. This includes adapting the inspection parameters and algorithms to the specific geometries and material properties of the hairpins.
Inspection of transitions to insulated copper segmentsweldAI can inspect the transitions to insulated copper segments to detect insulation cracks. This is critical to ensure the electrical safety and reliability of stators.
AI analysisweldAI provides optimized data for AI training, but does not offer pre-trained AI in the basic configuration. On request, we can train an AI that is tailored to your specific application. This includes the automatic detection of measuring points as well as a detailed qualitative analysis of the weld seams and other relevant features. You can therefore be sure that the AI is optimally tailored to your individual requirements and delivers precise results.
Application Examples
Customer Benefits and ROI
High-quality multi-perspective images for comprehensive analyses
weldAI captures high-quality multi-perspective images from several angles with just one camera and a single shot. This enables a comprehensive analysis of the weld seams and the geometry of the hairpins without having to move the test object.
Reliable inspection even in narrow gaps and with difficult reflections
weldAI enables reliable inspection even in narrow gaps between hairpins, where conventional methods reach their limits. Precise evaluations are guaranteed even with difficult reflections, which enables high inspection accuracy.
Improved defect detection through multi-angle detection
Up to 9 viewing angles ensure fewer false alarms and better detection of defects. This minimizes the risk of defects and ensures high quality weld seams. weldAI can also capture and analyze data when the object is in motion. This enables inline-capable inspection.
Revolutionary quality control through precision and adaptability
Revolutionize your quality control with unparalleled precision and adaptability. weldAI enables comprehensive quality control tailored to your specific requirements.
