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“As advantageous as hairpins are as a finished product, their manufacture is demanding, especially when it comes to bending and welding,” explains Georg Knoll, supervisor of welding processes at GROB and head of the workshop testing laboratory. “That's why we have to constantly check from incoming goods to the finished assembled part.” Because undetected defects can lead to loss of performance or inoperability, and in the worst case even to fatal damage to the entire drive.

Initially, after the tensile test, a cross-section of the copper wire for the hairpins is analyzed under the microscope to check the condition of the insulation coatings. Once the hairpins are assembled in the laminated core, the welded ends of the hairpins are inspected using a computer tomograph. The assembled and welded stator is then inspected tactilely and visually to ensure matching dimensions and to rule out surface defects.

As coordinate measuring machines, GROB relies on ZEISS PRISMO – one of the most precise of its kind. ZEISS ScanBox functions as an automated optical 3D measuring machine – it simultaneously enables high process reliability and high throughput. And GROB also relies on proven ZEISS technology for microscopy with the ZEISS Axio Imager, an open microscope system for automated materials research.