Automate Laser Welding Efficiently with Modern Measurement Technology

Background

In electric motor assembly, the quality of welded hairpins is essential, as each motor typically contains between 160 to 220 hairpins welded together that directly influence performance. Ensuring consistent weld quality is therefore a key requirement in production. Maintaining a stable and high-quality laser welding process is challenging, as even small deviations in weld seams can lead to defective motors. This can result in production delays, increased costs, and additional rework.

Solution and Application

To address these challenges, senswork developed the ZScan® 360, an AI-powered 3D inspection system designed for inline use in stator production. The system uses a high-resolution 3D sensor to capture detailed data from each weld point, which is then analyzed in real time using deep learning algorithms. These algorithms detect even subtle deviations in weld quality and identify patterns that traditional rule-based systems cannot reliably recognize. In addition to defect detection, the system provides valuable feedback on process variations, supporting continuous improvement in upstream manufacturing steps.

Results

The implementation of the ZScan® 360 significantly improves the accuracy of weld inspection while enabling fast, automated quality control. Real-time analysis allows immediate detection of defects and minimizes rework. Safety is also increased since there is a reduced risk of defective motors. As a result, manufacturers benefit from increased production efficiency, lower costs, and consistently high product quality.

For more examples of complex vision solutions, scroll through this list.