Case Study: Volkswagen achieves series production-ready quality assurance for electric drive stators with Carl Zeiss measuring technology

Volkswagen scales hairpin stator production with Carl Zeiss for 100+ hairpin quality checks

Volkswagen faced a challenge in assuring the quality of the innovative hairpin stators for its new electric drive at its Salzgitter plant. The physical properties of the copper hairpins, being easily deformed, shiny, and semi-transparent, made them unsuitable for traditional tactile and optical measuring methods. To enable large-scale series production of its electric vehicles, Volkswagen needed a comprehensive measuring solution and partnered with Carl Zeiss.

Carl Zeiss implemented a solution using a ZEISS PRISMO multisensor coordinate measuring machine equipped with VAST XXT, LineScan, and DotScan sensors, along with custom fixtures. This allowed for precise tactile measurement of components and optical scanning of the complex winding head. The solution provided user-friendly operation for production staff and clear data visualization with ZEISS PiWeb, enabling Volkswagen to efficiently conduct quality checks and ensure the safety and quality of its electric drive for series production.

Volkswagen