Details
| Original language | English |
|---|---|
| Pages (from-to) | 169-185 |
| Number of pages | 17 |
| Journal | Metrology |
| Volume | 3 |
| Issue number | 2 |
| Publication status | Published - 8 May 2023 |
Abstract
The increasing demand for electric drives challenges conventional powertrain designs and requires new technologies to increase production efficiency. Hairpin stator manufacturing technology enables full automation, and quality control within the process is particularly important for increasing the process capacity, avoiding rejects and for safety-related aspects. Due to the complex, free-form geometries of hairpin stators and the required short inspection times, inline reconstruction and accurate quantification of relevant features is of particular importance. In this study, we propose a novel method to estimate the creepage distance, a feature that is crucial regarding the safety standards of hairpin stators and that could be determined neither automatically nor accurately until now. The data acquisition is based on fringe projection profilometry and a robot positioning system for a highly complete surface reconstruction. After alignment, the wire pairs are density-based clustered so that computations can be parallelized for each cluster, and an analysis of partial geometries is enabled. In several further steps, stripping edges are segmented automatically using a novel approach of spatially asymmetric windowed local surface normal variation, and the creepage distances are subsequently estimated using a geodesic path algorithm. Finally, the approach is examined and discussed for an entire stator, and a methodology is presented that enables the identification of implausible estimated creepage distances.
Keywords
- 3D feature extraction, creepage distance, hairpin technology, production metrology
ASJC Scopus subject areas
- Engineering(all)
- Engineering (miscellaneous)
- Physics and Astronomy(all)
- Physics and Astronomy (miscellaneous)
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In: Metrology, Vol. 3, No. 2, 08.05.2023, p. 169-185.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Creepage Distance Estimation of Hairpin Stators Using 3D Feature Extraction
AU - Grambow, Niklas
AU - Hinz, Lennart
AU - Bonk, Christian
AU - Krüger, Jörg
AU - Reithmeier, Eduard
N1 - Publisher Copyright: © 2023 by the authors.
PY - 2023/5/8
Y1 - 2023/5/8
N2 - The increasing demand for electric drives challenges conventional powertrain designs and requires new technologies to increase production efficiency. Hairpin stator manufacturing technology enables full automation, and quality control within the process is particularly important for increasing the process capacity, avoiding rejects and for safety-related aspects. Due to the complex, free-form geometries of hairpin stators and the required short inspection times, inline reconstruction and accurate quantification of relevant features is of particular importance. In this study, we propose a novel method to estimate the creepage distance, a feature that is crucial regarding the safety standards of hairpin stators and that could be determined neither automatically nor accurately until now. The data acquisition is based on fringe projection profilometry and a robot positioning system for a highly complete surface reconstruction. After alignment, the wire pairs are density-based clustered so that computations can be parallelized for each cluster, and an analysis of partial geometries is enabled. In several further steps, stripping edges are segmented automatically using a novel approach of spatially asymmetric windowed local surface normal variation, and the creepage distances are subsequently estimated using a geodesic path algorithm. Finally, the approach is examined and discussed for an entire stator, and a methodology is presented that enables the identification of implausible estimated creepage distances.
AB - The increasing demand for electric drives challenges conventional powertrain designs and requires new technologies to increase production efficiency. Hairpin stator manufacturing technology enables full automation, and quality control within the process is particularly important for increasing the process capacity, avoiding rejects and for safety-related aspects. Due to the complex, free-form geometries of hairpin stators and the required short inspection times, inline reconstruction and accurate quantification of relevant features is of particular importance. In this study, we propose a novel method to estimate the creepage distance, a feature that is crucial regarding the safety standards of hairpin stators and that could be determined neither automatically nor accurately until now. The data acquisition is based on fringe projection profilometry and a robot positioning system for a highly complete surface reconstruction. After alignment, the wire pairs are density-based clustered so that computations can be parallelized for each cluster, and an analysis of partial geometries is enabled. In several further steps, stripping edges are segmented automatically using a novel approach of spatially asymmetric windowed local surface normal variation, and the creepage distances are subsequently estimated using a geodesic path algorithm. Finally, the approach is examined and discussed for an entire stator, and a methodology is presented that enables the identification of implausible estimated creepage distances.
KW - 3D feature extraction
KW - creepage distance
KW - hairpin technology
KW - production metrology
UR - http://www.scopus.com/inward/record.url?scp=85183460026&partnerID=8YFLogxK
U2 - 10.3390/metrology3020010
DO - 10.3390/metrology3020010
M3 - Article
AN - SCOPUS:85183460026
VL - 3
SP - 169
EP - 185
JO - Metrology
JF - Metrology
IS - 2
ER -