The future of manufacturing: machine vision for electric motors
As the central components for the electromobility of vehicles, e-motors are the focus of the automotive industry. Machine vision plays a decisive role in fulfilling the quality requirements.
With machine vision, for example, electrostatics, battery casings or battery contacts can be precisely measured. In addition, processes such as the laser welding of hairpins or busbars can be monitored using senswork systems. In doing so, it improves product quality, reduces rejection rates, increases customer satisfaction and, at the same time, promotes electric mobility.
Monitoring the laser welding of hairpins.
ElectrostatorWhen electric motors are assembled, around 160 to 220 hairpins are welded together. With senswork's AI-based inspection system, high-resolution data from the welding points are recorded and evaluated. This is how laser welding can be automated and process quality guaranteed.
Inline measurement technology along the process chain
3D Measurementsenswork offers solutions for the entire battery cell production process. With our optical 3D measuring systems, we can measure products in real time without contact and compare them against CAD, for example, the 3D measurement of battery clusters to enclosures, battery casings and contacts.
3D CAD comparison for busbars
Busbarssenswork's 3D measuring system records the geometry of busbars in just a few seconds. Deviations in shape can automatically be detected by comparing the nominal and actual surface profiles. Correction parameters for feed and bending angle per segment are continuously and automatically determined.
Quality control when foaming battery cells
Foamsenswork has developed a process for 3D scanning of foam surfaces between battery cells. Deformations such as cavities or foam protrusion are quickly and reliably detected. This ensures that the battery foam can optimally fulfill its safety-critical function.
Cell, Module, Pack | Prismatic Cells
Quality Control of the Bursting Disc2D and 3D inspection and AI enable the verification of safety-related components such as safety valves or bursting discs for defects and deviations. This ensures that pressure relief protection functions reliably in every cell.
Module, Pack | Prismatic & Round Cells
Inspection of Battery TerminalsBefore welding, we use surface analysis, 2D/3D vision, and Neuralyze® to check the battery cell connections for contamination, correct geometry, precise alignment, and intact surfaces – thus ensuring reliable and safe welding.
Pack Assembly | Prismatic & Round Cells
Distance MeasurementDistance measurements before welding ensure precise spacing, accurate alignment, and contact between components – especially between connections and busbars – to ensure long-term electrical reliability.
Module, Pack | Prismatic & Round Cells
Pre-Weld Pack & Module InspectionThe 3D inspection before welding ensures the correct geometry, fit, flatness, and alignment of all weldrelevant components, reducing the risk of poor welds, mechanical stress, and electrical failures in the final battery module or pack.
Cell, Module, Pack | Prismatic & Round Cells
Dimensional and Geometric Inspection
Dimensional and geometrical verification ensures that battery cells, packs, and modules have the correct height, width, thickness, flatness, and alignment to guarantee
proper fit and weld quality during assembly.
Prismatic and Round Cells
Weld Quality VerificationOur Neuralyze® vision AI software systematically checks weld seams for structural and electrical quality to ensure functional safety in EV battery modules and packs.
Pack Assembly
3D Measurement of BusbarsOur 3D system ZScan® ensures the precise geometry of the busbars for seamless integration into the battery pack. The measured profile is directly compared with the CAD model so that even the smallest deviations are detected and correction parameters for the bending machine are automatically determined.
Efficient automation of laser welding of hairpins for electric motors with AI. 100 % inline inspection for optimal quality.
Quality control in the automated production of busbars. The 3D measuring system ZScan® reliably detects shape deviations of busbars.
