Flexible Gauging For Ev Rotors And Gear Shafts
The quickly increasing demand of Electric vehicles is leading manufactures to produce high volumes in a very short amount of time. Total quality controls of the parts in production is a pivotal aspect of those new production lines since the expected level of production efficiency is tremendously high. This scenario clearly explains why most of leading EV manufactures today are using flexible measurements systems for in-line quality controls. Solution such as the OptoQuick and the Optoflash deliver precision and speed at the same time, for quality controls on gear and rotor shaft in the production environment.
Shaft workpieces are loaded by the operator or a robot into the vertical measuring system, through live centers. The workpiece is put in rotation by the integrated motorized spindle while the optical system acquires the images of the features to control.
Through images, features such as diameters or radii can be inspected and measured. Form controls, as for instance roundness or run out, can be executed as well.
High resolution image sensors guarantee the requested measurement precision, generally in the range of few microns of tolerance.
Image formation is executed through shadow casting. Which means the workpiece is measured through the shadow of its profile. The shadow casting technique is fundamental to achieve high metrological performance, removing any variability due to part color or surface finishing.
Contact sensors can be integrated as options in the system in order to enable the measurement of features not visible in shadow casting mode, as for instance key slots or dimensional characteristics of external splines, typically present in Rotor Shafts.
ALL-IN-ONE ROTOR GAUGING FOR DIMENSIONAL & MAGNETIC FIELD MEASUREMENT
Large Rotors can be measured on the OQL version even after magnetization, without any influence on the measurement performance.
The integration of a suitable optional kit allows the measurement of the magnetic field generated by a permanent magnet rotor.
Complete dimensional measurement (with optical and contact technology) and magnetic field mapping (via 3-axis Hall sensor) can be performed in the same gauge, in a single placement and correlated with each other.
The magnetic field measurement is three-dimensional: the components in radial, tangential and parallel direction respect to the rotation axis are measured.
The measurement can be performed on different sections and at a programmable distance, and allows the position of the magnetic poles and their phasing to be identified with respect to a reference on the shaft. With the same phasing, it is possible to measure the trend of the magnetic field along the rotation axis and analyze the edge effects near the ends of the rotor.
Performing the magnetic field measurement in combination with the dimensional measurement at the end of the rotor production line allows you to quickly identify any defective components and remove them before they are sent to the next assembly operation.
The magnetic field measurement of the rotor can also be very useful in the development and fine-tuning phase of the production process, to verify that the actual distribution of the magnetic field corresponds to what was planned in the design phase.
The magnetic field measurement is a preliminary and complementary test to functional control of Back EMF. Performing a magnetic field mapping with OQL at the end of the rotor production line allows you to proceed with the subsequent assembly phases and perform the Back EMF test more easily and with a reduced scrap rate on the assembled motor.
- Flexible solution, configurable for many different workpieces
- Easy definition of the measurements through the integrated user interface
- Dimensional and form controls.
- Measurements usable as machine tool feedback
- Possible integration of two controls, dimensional and magnetic field, within the same gauge, with consequent savings in costs, space and measurement time.
- Manual and robot loading
- Optical and contact measurement capabilities
- Magnetic field measurement kit perfectly integrated with the other OQL functions
- Measurement uncertainty up to 1µm
- Solution for workpieces up to 1200 mm in length and 240 mm diameter
