Harrandt measures hairpins faster than the eye can blink.
With an intelligent test module, we make it easier for our customers to install hairpins without errors.
In stator production, manufacturers rely on the highest precision so that the individual hairpins with special curvature are absolutely identical in their geometric features and can be safely installed. That is why our e-mobility customers trust in Harrandt's technological know-how and process-oriented approach.
Starting Point and Challenge
Fluctuations in the hairpin wire quality as well as different methods of cutting to length and bending can result in finished hairpins deviating minimally in size and angle of bend. This can cause serious problems in e-motors during the subsequent assembly. In order for our customers to meet their requirements for the error-free assembly of hairpins and the highly precise setting of the hairpin legs, they rely on Harrandt's expertise to optimize their production processes. The objective: a safe and reliable check of the function-critical bending angles and lengths - taking into account the fast cycle time of 1 second.
We were able to prove the technical feasibility of the demanding task with preliminary tests at the inquiry stage. We then carried out a series of tests with different image processing systems to ensure the required resolution for error detection. We had to take into account various special bends in the hairpins and calibrate the system, and our own developed evaluation software, accordingly. At the same time, we had to devise a suitable transport system that would transport the hairpins quickly but stably and would allow for high-precision measurements to take place. The finished solution is: The hairpin is transferred to the transport system by a robot and measured by two parallel scanners at a transport speed of up to 2 m/s. The data is calculated into a point cloud so that the evaluation software can check both the angle of curvature and other dimensions such as leg lengths, stripped areas and straightness of the hairpin legs. The final high-voltage test ensures that no damage was caused to the insulation layer of the hairpin during the bending process.
Reliable and process-stable measured data despite sensitive components - Harrandt technology makes it possible.
Our hairpin test module now enables an automated test system in which every hairpin is measured and checked for deviations before assembly. Random measurements or manual testing using form templates are no longer necessary. In addition, matching ensures the best possible assembly of the hairpins. Another great advantage of the hairpin module is that it can be easily retrofitted in existing lines.
Our case studies
Harrandt goes Cobot.
With the use of collaborative robots, Harrandt stabilizes production processes, maintains quality standards and facilitates the work processes of the workers.
Harrandt goes Digital.
The wire test module for testing and quality assurance of coated enamelled copper wires is our prime example of the possibilities of the IoT.
Pfisterer recognizes quality defects faster and more reliably - and with Harrandt finds even the tiniest defect.
A 360° endoscope camera enables the specialist company for energy transmission to reliably detect the smallest surface defects in high-voltage insulation bodies.