Optical Gauge For Hairpin

Whatever the technology adopted for the production of hairpins, with die bending or CNC machines, these are normally processes characterized by slow trends, which are well suited to being controlled by off-line sample measurement.

On the other hand, since these are easily deformable components, it is absolutely necessary to adopt accurate, but contactless, measurement technologies that allow for the exact measurement of dimensions, geometry and shape of the hairpins in the conditions in which they will be in the subsequent assembly phases.

The proposed solution, is an optical measuring system, able to perform the dimensional verification of the main geometric characteristics of the hairpin. Using three high resolution cameras the most important sections of the component are measured with the aim to keep under control lengths, widths and bendings to avoid problems during the stator assembly.

Thanks to the accurate calibration procedure of the cameras, the system is able to measure with maximum precision in a few seconds the main geometric and dimensional features of the hairpins.

Length of the hairpin legs Length of the stripped sections Width of the hairpin (distance between legs) in several sections Bend angles Twist angle Dimensions of the roof-top Skip bending Profile evaluation

The system guarantees maximum flexibility for measuring the different types of hairpins that need to be assembled in the stator, without the need for any mechanical retooling but simply by selecting the dedicated control plan.