Design and Validation of an Inline Curvature Measurement for Flat Wire Straightening in Hairpin Stator Production

Preitschaft A, Baader M, Mayr A, Bader T, Franke J, Kühl A (2025)

Publication Type: Conference contribution

Publication year: 2025

Publisher: IEEE

Pages Range: 1-8

Conference Proceedings Title: 2024 14th International Electric Drives Production Conference (EDPC)

Event location: Regensburg

DOI: 10.1109/EDPC63771.2024.10932837

Abstract

This paper presents a novel inline sensor-based method for measuring the curvature of straightened flat wires during hairpin stator production. The accurate control of the wire curvature is essential to ensure precise alignment in subsequent assembly steps. Existing methods for curvature assessment often rely on an external measurement in dedicated metrology stations or subjective visual inspection, both of which have significant limitations in terms of accuracy, consistency and time efficiency. The inline method proposed in this work offers a promising alternative that enables continuous, high-precision curvature measurement immediately after the straightening process. To evaluate the feasibility of the system, an experimental study is conducted in which straightened wire samples are analyzed using both the developed inline sensor system and an offline 3D optical profilometer as a reference. The results are then compared to determine the suitability and the accuracy of the inline measurement technique for industrial applications. The results indicate that the inline system provides reliable curvature measurements, demonstrating its potential to significantly improve quality control, reduce scrap and increase the overall efficiency of wire straightening processes in electric motor production.

Authors with CRIS profile

Involved external institutions

Omron Electronics GmbH Germany (DE)

How to cite

APA:

Preitschaft, A., Baader, M., Mayr, A., Bader, T., Franke, J., & Kühl, A. (2024). Design and Validation of an Inline Curvature Measurement for Flat Wire Straightening in Hairpin Stator Production. In 2024 14th International Electric Drives Production Conference (EDPC) (pp. 1-8). Regensburg, DE: IEEE.

MLA:

Preitschaft, Anja, et al. "Design and Validation of an Inline Curvature Measurement for Flat Wire Straightening in Hairpin Stator Production." Proceedings of the 2024 14th International Electric Drives Production Conference (EDPC), Regensburg IEEE, 2024. 1-8.

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