Measurement of Hairpins of an eMotor Stator

EV motor stators typically contain many copper hairpins; the exact number depends on the individual motor design. These thin wires form the motor’s electrical windings. As they are crucial for electrical behavior, magnetic flux, and heat generation — ensuring proper motor function — each hairpin must be precisely checked for position, orientation, and dimensions against the nominal CAD.

Our solution: eMotor Stator Inspection

Automate your EV stator hairpin evaluation with the eMotor Stator Inspection app for ZEISS INSPECT. The software significantly accelerates your quality control, ensures traceability, and eliminates manual interpretation.

Get precise results using 3D scans

The eMotor Stator Inspection app is a powerful tool for digital hairpin measurement based on non-contact 3D scanning data. The workflow is fully integrated in ZEISS INSPECT: The stator is digitized using a high-resolution 3D scanning system. Inspection tolerances are set directly in the app.

The software automatically analyzes relevant features, such as pin height, pin position, pin torsion, creepage distance, and air gap distance. It clearly shows if values are inside or outside of tolerance, giving the operator a very compact and immediate understanding of the part’s quality. The user can also display the exact values in a table format and export them for further analysis.

Learn more here.