ZEISS EMOBILITY SOLUTIONS

Quality Assurance for Rotors and Shafts

Dimensional measurement and porosity analysis

E-motor performance through rotor and shaft quality

Tight tolerances and critical parameters

The rotor comprises the shaft, the sheet stack, and built-in permanent magnets. Due to the high performance and speed of the e-motor, the rotor must meet very tight shape and location tolerances that require inspection. The air gap between the rotor and the stator bore is one of the main parameters that define the performance and efficiency of the e-motor. It is also critical with respect to safety and reliability. 

Key quality challenges for rotors and shafts

Rotor dimension measurement

Long stylus measurement of features

Since the rotor’s magnetic field can affect results by deflecting the stylus or the inside of the probe, it is essential to use long and heavy stylus systems for measuring dimensional features with the tightest tolerances. ZEISS CMMs with active scanning technology are ideal for these requirements. Long stylus extensions enable measurement at each position of the rotor, keeping the probe far enough away from the strong magnetic field to ensure stable and accurate results.

ZEISS CMMS

Shape and contour measurement

Quality inspection with tight tolerances

Fast rotation speeds mean that the shafts in NEVs must undergo swift quality inspection, especially in terms of shape and position tolerances. As shaft geometries change and tolerances narrow, CMMs make it possible to remain within these ranges while reducing throughput times and increasing predictability. A versatile ZEISS CMM featuring a highly accurate rotary table on air bearings and a diamond stylus kit is ideal for reliable results with shafts of all sizes.

ZEISS CALYPSO software

Porosity analysis

Inspection of defects in the short circuit ring of the rotor

Increasing speeds in e-motors mean that rotors must now offer significantly higher strength and stability. To prevent the rotor from breaking during operation, a certain porosity level must not be exceeded. Computed tomography from ZEISS is used to determine the size and number of pores in the rotor’s short-circuit ring. ZEISS software then analyzes and classifies the recorded 3D data by means of porosity analysis.

ZEISS VoluMax 9 titan

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