Stator Slot Optical Inspection for Burr and Geometry Detection
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Solution Overview
Problem
Current methods for inspecting electric motor stators, particularly stator slots, face challenges in efficiently detecting defects like burrs and geometric variations due to misalignment of laminations, which can lead to sub-optimal performance and failure.
Innovation Solution
An optical inspection system that includes a tilting mechanism and imaging device with a telecentric lens, allowing for precise alignment and measurement of stator slot dimensions by rotating the stator stack to capture images from multiple orientations, analyzing illumination, and detecting deviations from desired geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for stator slots, then the inspection process is simple, but the detection accuracy of defects like burrs and geometric variations is insufficient
Solution Approach 1:
The patent transitions from 2D surface inspection to 3D volumetric inspection by illuminating through the stator slot from the rear and capturing images from the front. This multi-dimensional approach allows light to pass through the slot and reflect off features like burrs, enabling detection of geometric variations that cannot be seen from a single viewpoint.
Solution Approach 2:
The patent introduces illumination as an intermediary element that passes through the stator slot to reveal defects. By using light as a mediator between the inspection system and the slot features, the system can detect burrs and geometric variations through their interaction with light, rather than direct mechanical contact or surface-only optical inspection.
2Measurement precision
If multiple images are taken from different orientations to measure depth and width, then measurement accuracy improves, but inspection time increases
Solution Approach 1:
The patent employs periodic rotation of the stator stack to capture images at specific orientations (0 degrees for width, 90 degrees for depth). This periodic positioning allows the system to collect necessary dimensional data at discrete intervals rather than continuously, reducing total inspection time while maintaining measurement accuracy.
Solution Approach 2:
The system performs preliminary alignment and positioning of the stator stack before image capture, ensuring that the slot is properly oriented relative to the imaging device. This preliminary action prevents the need for multiple corrective adjustments and retakes, streamlining the inspection process.
3Reliability
If the stator stack is rotated to multiple orientations for inspection, then comprehensive defect detection is achieved, but the complexity of the tilting system increases
Solution Approach 1:
The patent divides the inspection process into distinct segments: width measurement at 0-degree orientation and depth measurement at 90-degree orientation. This segmentation allows the tilting system to focus on achieving specific angular positions rather than continuous multi-axis movement, simplifying the overall system architecture.
Solution Approach 2:
The tilting system is designed to perform multiple functions: it rotates the stator stack for both width and depth measurements, positions the slot in the field of view, and enables comprehensive defect detection from different orientations. This multi-functionality reduces the need for separate specialized mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and accurate detection of defects and deviations in stator slots, improving manufacturing efficiency and quality control by ensuring optimal alignment and measurement conditions during the inspection process.
Implementation Method 1
An optical inspection system that includes a tilting mechanism and imaging device with a telecentric lens, allowing for precise alignment and measurement of stator slot dimensions
Implementation Method 2
an illumination device configured to apply the illumination from a location below the stator slot
Data Source
AI summary
A method of inspecting a stator stack includes disposing the stator stack on a support surface of an inspection system, and performing a depth measurement of a stator slot. The depth measurement includes rotating the stator slot along a first direction to a plurality of first orientations, taking a first image at each of the first orientations, and measuring a depth based on at least one of the first images. The method includes performing a width measurement of the stator slot, which includes rotating the stator slot along a second direction to a plurality of second orientations, taking a second image at each of the second orientations, and measuring a width based on at least one of the second images. The method further includes inspecting edges of the stator slot in the at least one of the first images to detect a potential deviation.