The global market for new energy vehicles (NEVs) is growing rapidly: sales of electric vehicles are expected to reach more than $800 billion by 2027. The sharp increase in demand for electric vehicles has put more pressure on manufacturers and OEMs, especially when it comes to quality assurance, and those fast-growing EV companies must deal with new challenges and break through bottlenecks. With a wide range of new energy vehicle solutions and more than 1,000 customers worldwide in the NEV sector, ZEISS has become one of the most important partners in the industry.
bob chen
ZEISS Industrial Quality Solutions, Global Head of New Energy Vehicles.
In terms of quality management, major OEMs and battery and motor manufacturers** have partnered with ZEISS Industrial Quality Solutions. ”
NEV reform
With the development of the new energy vehicle industry, the originally "ancient" industry of motor and electronic control has radiated new vitality and experienced a fierce change. Benefiting from the rapid growth of the vehicle market, the motor and electronic control market is also showing a trend of rapid growth. Relevant data show that in 2023, the market size of China's new energy passenger vehicle motor and electronic control will likely be close to 10 million sets. It is expected that by 2030, it will exceed 18 million units. Such a huge market scale is bound to cause fierce market competition, among which, it is very important to ensure the quality of motors and power devices under large-scale production.
Efficient measurement of flat wires and stators
Manufacturers bend coils into the shape of flat wires during the production of electric vehicles. These flat wires consist of flat copper wires and are coated with an insulating layer. During stator assembly, the size and position of these flat wires must be checked, as they are highly deformable and their ends are difficult to weld.
Coils are extremely sensitive to contact, so optical measuring devices are a good solution for quality control of flat wires. Another reason for using it as a quality control solution for flat wires is that the geometry and position of the flat wires can only be verified with full-field 3D data. ZEISS has been cooperating with manufacturers of electric motors and flat wire stators in this field for many years. The new ZEISS Scanbox for eMotors is a compact 3D measuring system that has been developed for very fast and reliable scanning of highly reflective insulation on flat wires. With the click of a button, optical 3D measuring devices capture the 3D coordinates of individual flat lines and the freeform surface of the entire stator and provide high-resolution quality information in seconds. The ZEISS software can then present the results in a clear, easy-to-understand layout.
The Zeiss ScanBox includes powerful inspection software for detailed 3D data evaluation.
The software performs complete analytical measurements, such as shape, angle, and position tolerances of the hairpin, as bending points and bending radii.