Inline 3D metrology for stable wire straightening processes in electric motor manufacturing
At Coiltech in Augsburg (March 25-26, 2026), senswork will present a new optical inline measuring system. With WireShape3D, geometric deviations in the wire straightening process for hairpins can be detected and stabilized at an early stage.
In hairpin production, the wire is unwound from the coil, straightened, then bent, cut, inserted into the stator, and welded. Although this process is highly automated, material-related fluctuations repeatedly lead to shape deviations. Even minimal residual curvatures or twists after straightening can lead to significant dimensional and positional deviations later in the process.
Deviations that remain undetected during the ongoing process are particularly critical. A single defective hairpin can cause great damage if it only becomes noticeable when it is inserted into the stator. In practice, this means that if just one hairpin - perhaps the last of several hundred - is not seated correctly, the entire stator may be scrapped. Reliable detection of the actual wire condition is the key to effectively avoiding scrap, rework, and ROI losses.
Inline 2D and 3D measurement technology for active process stabilization
With WireShape 3D, senswork offers an innovative solution to this challenge. The optical inline measurement system is integrated directly after the straightening machine and before the bending process and checks the straightened wire continuously and without contact during operation.
The transmitted light camera detects the remaining curvature of the wire in the X and Y directions. In addition, two 3D sensors measure the wire cross-section to reliably detect any axial twisting (torsion). These measurements yield three geometric parameters that enable a complete three-dimensional assessment of the wire condition.
The measurement data is available in real time and can be fed back to the upstream straightening system. On this basis, the straightening process can be dynamically adjusted to specifically compensate for different parameters when unwinding the coil. The aim is to achieve a consistent, reproducible wire condition as a stable basis for the subsequent bending process.
Quality assurance before the bending process
WireShape 3D enables process-oriented inline quality control immediately before forming. Geometric deviations are detected before they can affect the bending process or later assembly steps. Non-contact measurement ensures that the wire remains unaffected even at high feed speeds. The system thus supports consistently high component quality and significantly reduces the need for rework.
WireShape 3D at Coiltech Augsburg
senswork will be demonstrating WireShape 3D in action at Coiltech Germany in Augsburg. Visitors can experience live how residual curvature and torsion are measured inline and how the measurement data is used to stabilize the straightening process. Automobile manufacturers, Tier 1 suppliers, and machine builders will gain practical insight into a flexible solution for optimizing hairpin production processes in electric motor manufacturing.
Image 1: Unique – WireShape 3D measures the curvature and torsion of the wire completely three-dimensionally and close to the process. (source: senswork)
Image 2: The 3D scanner setup enables precise 3D measurement of the wire. (Image: senswork)
Image 3: The camera uses mirror units to capture the wire geometry in transmitted light from two perspectives. (Image: senswork)
Image 4: The VisionCommander displays the inline measurement data in real time. (Image: senswork)
Press Contact
Hedwig Unterhitzenberger
+49 8677 409958-37
hedwig.unterhitzenberger@senswork.com
senswork GmbH, Gewerbepark Lindach D 3, 84489 Burghausen