This paper presents a novel inline sensor-based method for measuring the curvature of straightened flat wires during hairpin stator production. The accurate control of the wire curvature is essential to ensure precise alignment in subsequent assembly steps. Existing methods for curvature assessment often rely on an external measurement in dedicated metrology stations or subjective visual inspection, both of which have significant limitations in terms of accuracy, consistency and time efficiency. The inline method proposed in this work offers a promising alternative that enables continuous, high-precision curvature measurement immediately after the straightening process. To evaluate the feasibility of the system, an experimental study is conducted in which straightened wire samples are analyzed using both the developed inline sensor system and an offline 3D optical profilometer as a reference. The results are then compared to determine the suitability and the accuracy of the inline measurement technique for industrial applications. The results indicate that the inline system provides reliable curvature measurements, demonstrating its potential to significantly improve quality control, reduce scrap and increase the overall efficiency of wire straightening processes in electric motor production.
Design and Validation of an Inline Curvature Measurement for Flat Wire Straightening in Hairpin Stator Production
2024-11-26
788950 byte
Conference paper
Electronic Resource
English
Simulation and Validation of Stator Modes of a Hairpin Motor
SAE Technical Papers | 2023
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