From energy
to eMotion

ZEISS eMobility Solutions

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From energy to eMotion
Because of the large demand for electric vehicles all over the world, the automotive
industry is seeing a rise of the electric engine and powertrain. This results in increasing
demands on precision and poses new challenges to the quality assurance process.
ZEISS Industrial Quality Solutions is the expert when it comes to developing new testing,inspection and metrology concepts for electric vehicle components. This has beenachieved with joint projects, implemented in cooperation with the automotive andsupplier industry.
ZEISS eMobility Solutions features a selection of products from the ZEISS portfolio, providing unique holistic quality inspection solutions for all components of the E-Mobility:
Battery, Power Electronics, E-Motor and Transmission – From energy to eMotion.

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ZEISSeMobility Solutions

FUEL CELL SYSTEM
page 18

POWER ELECTRONICS
page 28

H₂

BATTERY
page 6

4

E-MOTOR
page 38

TRANSMISSION
page 505

BatteryA wide range of imaging, analytic and metrology tools are needed to enable
battery research and quality control of batteries. ZEISS produces light,
electron, x-ray-microscopy and computer tomography (CT) systems, as wellas coordinate measurement machines to assess and correlate structural,compositional, electrical and dimensional characteristics across the relevant
lengths scales. ZEISS thus helps to provide the relevant data to enable
battery safety and performance for new energy vehicles.

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BatteryMaterial

Electrode
Cell

Batteries play an important role in the performance,
range and longevity of an electric car. Safety, service
life, performance and cost are essential to ensuring the
success of battery technologies – both today and in the
future. These factors need to be addressed every stepof the way, from R&D to quality control and production.
It’s necessary to control and understand the propertiesof the battery down to the material, electrodes, cells,
modules and tray level.

Tray

Modules8

To produce efficient, reliable batteries that last, it isnecessary to use top-quality materials and precise
production techniques. Quality criteria range fromselecting the best possible materials – including
Lithium compounds, anode and cathode materials andseparator foils – to control critical steps during theelectrode manufacturing process. Understanding the
microstructure and possible sources of contamination is
key. It’s also essential to build cells, modules and trays
within very tight tolerances during final assembly.

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Materials
Recipe Development

NCM 811 Cathode Material

Designing new energy vehicles for
performance and cost begins withbattery technology. Developing newactive materials for the cathode,
anode and separator is key to improve the capacity, charging behavior and lifetime while controlling
costs.
For graphite anode materials, porosity and facile preparation are key todetermine discharging behavior.
While adding silicon to the anodecan increase energy density, it isnecessary to monitor and control
lifetime issues. Electron and X-ray
microscopy solutions from ZEISS
provide the necessary imaging andanalytical capabilities to determine
the relevant material properties –
critical for further advancing battery
performance and safety.

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Supply Chain Control

Liftetime & Aging EffectZEISS Laser Scanning Microscope

Conductivity Map Created with

(LSM) Copper Foil Cathode

Electron Microscopy

Controlling the quality of incoming goods is critical to ensure
uniformity and consistency in the
supply of materials. Key issues insupply chain control range fromthe qualification of raw material
powders, and the quality controlof the aluminum, copper andseparator foils. Light and confocal
microscopes from ZEISS can examine the surface roughness andmicrostructure of foils. Electron
microscopes control the elemental composition, particle size
distributions and/or particle contamination in raw material powders. Complete batteries can beinvestigated using X-ray microscopy to ensure a uniform supply.

The performance of batteries changes over their lifetime, and it’s
critical to understand these longitudinal aging effects. Under a microscope, one can observe that charging and discharging createschemical and structural changes
that alter the electrode materials.
Repeated swelling and contractingof the battery leads to crack propagation, void evolution, loss of mechanical stability and electricalconnectivity, and thus capacity
fading or failure of the cell. ZEISSelectron microscopy allows for
microscale electrical property mapping, which makes it possible tocreate a “conductivity map” of theactive battery materials.

The battery system defines the experience of driving electric vehicles morethan any other element. The energy density of the cells defines power toweight ratio and driving range, and the time required for charging needs toalign with customer expectations. The battery pack is often the most expensive component in a new energy vehicle. Raw materials dominate thecost of battery cells, which is why designing a new energy vehicle requires
balancing performance against material costs without compromising safety.
ZEISS microscopy tools give battery engineers and materials scientists theinsights needed to overcome these challenges.

11Battery Cellwith Electrodes
Machine Vision

SafetyElectrode In-Line Inspection with

3D X-ray Microscope Tomography

ZEISS Machine Visionof a Pouch Cell

Anodes and cathodes are coatedwith copper or aluminum foils.
There are various possible surface
defects like foil defect and surface
cleanliness, but also coating defects such as bubbles, agglomerates and uncoated areas. ZEISS
microscopes can effectively detect, locate and qualify the highvariety of defects. It’s necessary todetect defects during this highspeed production as well. An
efficient ZEISS Machine Visionsystem can cover all of theserequirements, controlling andmonitoring at speeds that canensure effective quality inspection
at the same pace as the line.

Batteries are energy dense objects,
and like the fuel in conventional
vehicles safety needs to be managed to protect the end user. Electrical shorting between anode andcathode can lead to thermal runaway and combustion – so themicroscale properties of assembled
cells can give insights into designing safer high performance batteries. Prior to cutting or disassembly,
ZEISS X-ray microscopes can giveinternal 3D microstructure, show
bending of current collectors andpotential separator pinch points, aswell as particle contamination
which may lead to lithium dendrite
formation. Shock and nail penetration tests use light microscopy toinvestigate potential failure modes
following accident or collision.
Charge and discharge behavior,swelling & dendrite formation canbe observed using in-situ microscopy methods.

A battery cell is the main unit of a battery, which consists of key components like the cathode, anode, separator and electrolyte. The geometry of
the electrodes inside a cell is vital to the efficiency and safety of the cell.
Anodes, cathodes and the separator foils are all cut or punched out ofcoated copper, aluminum or insulation paper foils. The separate foils arestacked, ideally without any overlapping.

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Modules with Cells
Pack with Cells

Assembly & Safety
The battery cell is assuring the structural integrality of the battery andsafely confines the electrolyte and the chemical reaction taking place
inside. Since the chemical reaction is associated with the generation ofheat and swelling of the battery material, the internal arrange of thebattery components, the sealing of the cells and the arrange of the cells
into packs needs to be controlled.

Plug-in Hybrid Electric Vehicle (PHEV2) Stacking Cell:

Battery Pack Including Stacked andComplete Scan under Optimal Acquisition Parameters

Connected Cells

For the battery cell itself the stacking of the battery sheets inside thecell is critical, since misplacement can lead to short circuits. Uponassembly of the cells the distances between the battery material andthe cell housing needs to be controlled, as well as the position of thecurrent collector foils and the welding quality for e.g. the sealing. Last
but not least a defect free burst membrane and a correct electrolyte
filling level needs to be assured to guarantee overall battery safety
and performance. Non-destructive X-ray imaging and metrology canprovide answers to the above questions and thus are also able toreveal quality issues in the battery cell assembly process.

A battery pack has a huge numberof cells, which is why stacking andconnecting them is a fully automated process. Robots bring all of thedifferent cells and spacers between
them together to create battery
modules. Each complete battery
pack consists of a few battery modules. ZEISS coordinate measuringmachines are the ideal solution to
make sure every single cell is in theright position in the tray. Non-contact measuring technology like ZEISS
laser triangulation is safe and reliable due to the high voltage inside thebattery packs. ZEISS X-ray technology is a fast, non-destructive solution
to check the connection weld seams
between the single cells – ensuring
full functionality and capacity.

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Battery Tray

The battery tray is the battery receptacle on the car. It must be mechanically stable and fastened to the entire car body. However, it is nolonger a single part simply attached to an electric vehicle. Furthermore, the tray has become fully integrated into the car body. The complex
aluminum weld design contains all the battery cells, connectors, andcontrol units. Also, the battery packs including various number ofbattery modules.

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Position & Dimensions

Welded joints Quality

Inline Measurementin production

Full-field geometry
acquisition

Digital twin forprocess & quality
control

Digital assembly

Optical Laser Triangulation

Tactile Measurement of Battery Tray

Optical inline inspection of the

Optical measurements of a battery tray

Deviations between the digital twin

Determination of the gap size between

Measurement of Battery Tray on

on ZEISS Horizontal Arm CMM

Battery Traywith a 3D measuring machine

and CAD data

battery module and battery tray after

ZEISS Horizon-tal Arm CMM

Thermal expansion of the battery
pack during charging and driving
can lead to torsion and bending in
the tray. A variety of dimensional
characteristics, such as the length,
diameter and position of slots, must
be measured either using random
sampling or a complete automatedinspection at the end of the line. The
large number of features
requires quick inspection cycles
involving multi-sensor measurement.
ZEISS non-contact optical laser
scanners can quickly extract feature
data, while tactile probe systems
can reach undercuts and otherchallenging optical features.

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digital assembly

The tray must be properly
integrated in the car body
because of the large amount ofenergy in the battery cells – andto ensure the safety of thebattery in the event of a crash.
Connection points (i.e. weldedbolts) attach it to the rest of thecar body. The size and location ofthese welded points are important
for the fully automated battery
tray assembly process, and for the
structural connection to take load
forces during driving, charging
and in case of an accident. All ofthese requirements lead to a wide
range of different characteristics
that could be covered with flexible
user-defined probe systems or byscanning point clouds with ZEISS
optical sensors.

Due to the high number of geometric elements and weld joints
to be measured, as well as thesize of the battery tray, long measurement and inspection cycles
are quickly achieved. Since thebattery tray, as a safety-criticalcomponent, is very often required
to 100% monitoring, an inline
solution for production is requiredin addition to the reference
measurement in the measuringroom, in which the most importantelements are measured. ZEISS
offers various sensor systems forinline measurement and inspection technology. The sensors are
moved to the features to bemeasured by industrial robots,
which means that a very shortmeasuring time can be achieved
without the need to additionallyeject the battery tray.

Optical measuring machines fromGOM enable the full-field measurement of the battery tray withhigh-precision fringe projection.
They digitize the part within a shortperiod of time from different
viewing directions – with highaccuracy and detail resolution. The
sensors create absolute, correlationfree and traceable measuring data.
The user gets millions of full-field
distributed 3D coordinates that canbe compared to the CAD model todetect deviations and identify
defects such as deformations. By
using CAD data and inspectionplans, the software fully automatically creates sensor positions androbot paths required for acquisition.

The result of the measurement isthe digital copy, a digital twinthat shows the real geometry of
the battery tray. Process-related
inspection features, such as thelocation of the fixing holes, canbe extracted from the 3D point
cloud and be evaluated in a trend
analysis. With trend analyses
based on full-field measurements,changes in the production process can be spotted at an earlystage. During problem analysis,
the color-coded surface deviationsof the 3D point cloud facilitate
reaching the desired nominal CAD
geometry. By using GD&T functions, the flatness or surface
profile of sealing surfaces orindividual battery compartments
can be calculated. Likewise, theheight and position of the sealing
bead are easy to capture.

In the digital assembly, the interaction of the battery modules
with the battery tray can beassessed. Assembly situations canbe simulated and optimized via
different local alignments.
Questions about gap size changes
caused by thermal deformation of
the battery modules after cycle
tests can also be answered easily.
The surface deviations between
battery module and battery tray
can also be used to calculate thevolume of the required heat-conducting paste for the individual
battery compartments.

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H₂

Fuel cell system
In addition to Battery Electric Vehicles (BEVs), Fuel Cell Electric Vehicles(FCEVs) are another possibility for the future of alternative energy supply.
In a FCEV, the fuel cell system provides all of the energy needed to power
the electric motor. The fuel cell stack is the most important component of
the FCEV, this is where energy is being provided through electrochemical
reactions. In the fuel cell stack many individual cells are arranged in series
and connected together. The process to construct the fuel cell system
requires the highest quality standards in production and development ofeach individual component. These requirements can be achieved by using
ZEISS microscopy and ZEISS metrology solutions.
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H₂

Fuel cell system

Bipolar Plate

Peripheral
Components
MembraneElectrode Assembly22

At the heart of every Fuel Cell Electric Vehicle is thestack of low-temperature fuel cells with polymer
membranes (PEMFC); this is where the electrical energy
will be extracted from hydrogen. Each cell consistsof two bipolar half-plates and a Membrane Electrode
Assembly (MEA). Because the fuel cells are connected
in series, the quality of each cell is largely responsible
for the overall system. The high demands placed on
Bipolar Plates (BPP) and MEAs can be tested withdimensional metrology and by inspection of coatings,
surface defects including contamination, or weld seams.
ZEISS measuring instruments and image processing
methods are used to meet the quality requirements
within the entire value-added chain of fuel cell
production. Multisensor CMMs, computed tomography
and light microscopes make it possible to meet theserequirements. The results are clearly provided on
a component-related report, generated using thecomprehensive ZEISS PiWeb software and the uniform
software design of ZEISS solutions.

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H₂

Bipolar Plate
2D Geometry

3D Geometry &Microstructure

Bipolar Plate
Assembly
Often, more than one hundred individual fuel cells are connected to construct a single stack. The bipolar plate is the link between two adjacent cells.
It functions as a mechanical stability, the media flow and electrical connection to the next cell in the series. To efficiently generate electrical energy,
the quality of each individual cell must be guaranteed.

2D geometry analysis of a bipolar

3D geometry measurement of aAnalysis of the lateral displacement

half-plate on the ZEISS O-INSPECT

bipolar plateof a welded bipolar plate (BPP)For the large number of individual
cells, optical measurement offers
the necessary measuring speed andthroughput. The dimensional
accuracy of the outer contour, as
well as recesses and holes for media
routing, and geometric elements forstack alignment, can quickly andreliably be analyzed in a single planewith ZEISS O-INSPECT. This ensures
the subsequent joining of eachindividual plate and the subsequentassembly of the stack using reference edges and patterns.

Gas flow and coolant delivery aredesigned for high efficiency throughspecially designed microstructuresin the individual bipolar plates. To
guarantee the efficiency of the BPP
the curvature, edge steepness,position and periodicity of the 3D
microstructure must be ensured.
The ZEISS DotScan, a chromatic
white light measurement sensor, on
a CMM with a rotating probe headis capable of optically measuring
these characteristics. At the sametime, the waviness and burr formation on cut edges can also be detected. With suitable measurement on
both sides, the material thickness andlocal thinning of material by theforming process can also be recorded.

Two single half-plates are joined toform the bipolar plate. The circumferential weld seam seals the area ofthe coolant fluid, while additional
welds in the so-called flowfield
ensure electrical and mechanicalproperties. In this assembly state,
the ZEISS DotScan chromatic confocal sensor can be utilized to capture
the 3D structure on both sides. The
goal is to determine the lateralalignment of the welded plates withrespect to each other, as well as thedeviation in the total thickness.
Detailed 3D information in small
areas can be obtained using X-ray
microscopy with the ZEISS Xradia
Versa.

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H₂

Membrane Electrode
Assembly
2D Geometry of Planar Micrograph Analysis
Single Layersof the Finished MEA

Defect Analysis
of Electrode Layers

Measurement of a membrane electrode

Light microscope image of a preparedElectron microscope image of anassembly (MEA) on a ZEISS O-INSPECT

micrograph of the MEA stackelectrode coating including crack

Electrical energy is obtained from an electrochemical reaction that takes place in the Membrane
Electrode Assembly (MEA). In the center of the MEA there is the membrane (PEM), which only
allows the protons, i.e. the nuclei of the hydrogen atom, to pass through. Two electrodes, also
known as „carbon black“, are positioned on each side of the membrane. They contain the catalysts
that enable and accelerate the chemical reaction. The finished MEA additionally includes gas diffusion layers (GDL) on both sides. Depending on the manufacturing process, the electrodes are either
applied to both sides of the membrane (CCM) or to the respective GDL (CCL).

network

The position and orientation of
the individual layers, especiallythe electrodes, have a decisive
influence on the efficiency ofenergy conversion in the fuelcell. In addition to CCMs or CCLs,
unitized electrode assemblies(UEAs) are often used. The ZEISSO-INSPECT offers the perfectsolution to measure the sizes
and positions of recesses aswell as the positions of coatings
in relation to reference edges.
These characteristics can easily
be measured with the O-INSPECTs
optical edge detection technology
and its integrated backgroundlighting.
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During the development andtesting of the layer structure of
the MEA, samples sections areprepared through destructive
testing procedures. Using thesesamples analyze the continuityof layers, their thicknesses andorientations with respect to eachother are analyzed. Bright field or
confocal microscopy is a perfectsolution, for example using theZEISS Axio Imager.

The electrode layers are appliedvery thinly to the PEM (CCM)
or GDL (CCL) with a coating
thickness of only a few μm.
Coating processes and handlingcan influence the crack
formations on the electrodelayer. The analysis of thesecracks (width, length, branching,meshing) can be performed
using light microscopic images,
which can be captured using theZEISS Axio Imager. Cracks can befurther examined using scanningelectron microscopes, such as a
ZEISS GeminiSEM.

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H₂

Peripheral
Components
Stack AssemblyMedia-Carrying
Components

Compressors &Pumps
In addition to the fuel cell stack, there are many additional components that are relevant to thesystem. The hydrogen required for the chemical reaction is transported from storage units tothe stack via a piping system. In contrast, oxygen is obtained from the ambient air, which mustbe treated for this purpose. This process requires various components such as pumps, filters andwater separators. The quality of each component is crucial in order to construct an efficientfuel cell system.

Stack assembly of a Fuel Cell System

The individual BPP and MEA
units are packed tightly toconstruct a dense cell stack.
The structural geometries are
crucial as they must absorb
the pressure within the stackduring operation. The housingof the stack often consists of adie-cast aluminum construction.
To ensure the quality of thesecomponents, ZEISS computer
tomography is used to detect
defects, pores or inclusions in
the cast structure. In addition,
machined connection surfaces
are measured and evaluated togauge the dimension, shape andposition using tactile and opticalcoordinate measuring technology
from ZEISS.

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Porosity analysis of a media

Tactile measurement of a pump on acarrying plastic part

ZEISS coordinate measuring machine

Complex pipe systems are responsible for supplying hydrogen andoxygen to the fuel cell stack, aswell as removing cooling water.
The geometry and material
properties of these components
are very important for thefunctionality and durability of theentire system. To ensure this,ZEISS computer tomography cancapture 3D data from the real
injection molded component,
which can be used to detect
internal defects using ZEISS
software tools. In addition,wall thicknesses can be viewed
and measured, and a complete
nominal-actual comparison canbe calculated against the CAD
model.

Compressors, pumps, and water
separators are used to produce theproper conditions for the hydrogenand air to complete their chemical
reaction and the transport. For
these mechanical components,
dimensional measurement technology plays a major role. Optical andtactile sensors on a ZEISS CMM canbe used to certify the dimensions
regarding size, shape and positionof sealing surfaces, as well as bearing seats and other geometricelements.

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Power Electronics
Power electronics is the energy hub of every battery-electric, hybrid andfuel cell vehicle, as it controls the flow of power between the battery andthe electric motor. To make electronic components more efficient andreliable, it’s essential to control the quality of semiconductors, printed
circuit boards (PCBs) and finished modules across different length scales.

3031Power Electronics

Semiconductor

Housing

Printed circuit board (PCB)
Inspecting PCBs and connectors requires automated imaging and metrology
solutions at the mm scale with µm precision. Non-destructive X-ray inspections and metrology solutions help benefit the quality control and failure
analysis workflows of such components. Integrating electronic components
in modules and then installing these in the electric vehicle involve very tighttolerances, which can be controlled using optical or tactile coordinate
measurement systems. ZEISS has an extensive portfolio of products, including electron and X-ray microscopes for measurements down to the micrometer, as well as tactile measurement methods and automated image processing methods in the mircometer range.

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Connectors

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Semiconductor
Motor Control &Gate Drivers

Power Electronics
The control of the driving experience in new energy vehicles is increasingly compact and integrated within the electronic control system of thevehicle. Improvements in processing power, efficiency and cost allow
vehicles to manage external sensor inputs, motor feedback and remotetelemetry to augment driver inputs for a safe, efficient and enjoyabledriving experience. ZEISS microscopy solutions are used throughout theElectronic value chain.

Passive Voltage Contrast Image of an

3D X-ray Tomography of a Power Diode

Integrated Circuit (IC) Using Electron
Microscope

ZEISS microscope workflows arefound throughout semiconductor
IC design, manufacture and quality
control. ZEISS Gemini technology
offers a unique combination ofmaterial contrast, resolution andbeam stability for electron microscopy of semiconductor logic devices. ZEISS X-ray microscopy can beused to identify manufacturing
irregularities in semiconductor
packages and guide improvements
to process control, as well as nondestructively look for failure modes
such as delamination and cracks inelectrical contacts.

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High-power switching devices,such as Insulated-Gate Bipolar
Transistors (IGBT) and power
Metal-Oxide-Semiconductor FieldEffect Transistors (MOSFET), arecore technologies for delivering
controlled power from battery to
motor. Analytical electron microscopy techniques help map theelectrical and material properties
with submicron spatial resolution
to optimize the design and failure
analysis of these devices.

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Printed Circuit Board (PCB)
Quality Control & Failure Analysis
The increasing number of electronic components, the ever tidier integration of such and the harsh environment (e.g. temperature, vibrations)
makes the quality control and failure analysis of those components
necessary. This is especially true for new energy vehicles and autonomous driving cars since the electronic devices become safety relevant.

3D Visualization of a PCB Using X-ray

Optical Cross-Section View

High-Resolution Electron Microscopy

Microscopy

of a Capacitor

Imaging of Electronic Component on
PCB

Non-destructive printed circuit board (PCB) inspection using X-ray technology and/or optical inspection can reveal quality issues, which guide steps in
the failure analysis workflow to reveal the root cause. High-resolution imaging in 2D and 3D, analytical capabilities and optical metrology are needed
to control critical dimensions, surface roughness and topography, andpossible particle contamination. Automating such inspection tasks, including large-scale imaging, is required to produce increasing numbers ofelectronic components while meeting strict quality requirements.

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Housing & Connectors
Casting Inspection &Machined Dimensions

Injection Molding &Connectivity
The housing of the power electronics components plays an important role
when it comes to safety and reliability of the whole battery pack. It needs
to protect the battery electronics from external influences like vibrations,humidity and temperature changes, which could have a huge impact on
failure safety. The connectors and plugs to the battery modules also needto resist these described influences, ensuring easy, safe connectivity every
time the vehicle is used.

Housing of Power Electronics with

Connector X-ray Data Analysis with

Connectors

ZEISS NEO insights

Aluminum die casting is used to
produce thin, durable and lightweight casted walls. This saves
material and allows for precise
machining, essential for the fully
automated assembly of the powerelectronics package. Sealing surfaces require tight tolerances interms of flatness and roughness.
The positioning of the connector
plugs is also important to get electrical contact, which is reliable overa long time and many charging anddriving cycles. ZEISS and GOM
coordinate measuring machines
are the best solutions to achieve
geometry and roughness requirements as they cover all of the characteristics that involve tight tolerances, including the flatness androughness of seal surfaces and theposition of connector plugs.

Injection molding is the mostcommonly used technology tocreate connectors. This makes it
possible to combine a mix of plastics for the connector housing andmetal for the pins – a complex andvery fast process because of thehuge amount of connectors in a
vehicle. The position of every single
pin needs to be checked to makesure each electrical contact works.
The small size of the pins inside theconnector and the long and deep
geometry to measure with tactile or
optical technology present challenges.
ZEISS X-ray scanning technology canovercome this, quickly measuring,visualizing and analyzing huge
numbers of connectors. In addition
to measuring tasks, the X-ray
technology can also detect defects
inside the injection molding areas.

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Electric Motor
Electric motors are true powerhouses – compact and light, but still capable ofhigh speeds and enormous torques, even at slow speeds. All components needto fit together precisely for these motors to generate so much power with such
little wear. One challenge posed by the latest generation of motors involves theprecise production and assembly of the hairpins and stator, as well as the manufacture of the stacks in the stator and rotor. ZEISS produces tactile and opticalmeasuring devices to cover every aspect of the quality management process, andeven helps electric motor manufacturers set up their inspection chains.

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Electric Motor

Housing

StatorHairpins
Automated processes are involved in producing many of
the components found in compact high-performance
motors. For example, the current-carrying conductors inthe stator are no longer wound from many thin wires,but bent from solid copper wires, plugged together andwelded. While this bending action is fully automated, it
poses quality assurance challenges to measure the pin
shape and isolation lacquer thickness due to the flexible
structure of the pins. Eventually, these hairpins need to fit
into the exact grooves punched or cut into the stator
stack sheets. Such high-precision assemblies require
down-to-the-micrometer accuracy – and this is whereZEISS excels.
ZEISS offers tactile and different optical measuring devices such as 2D camera, laser triangulation and confocal
whitelight sensors to cover every aspect of the quality
management process – for efficient, reliable motors that
last. From handheld laser scanners to high-accuracy
coordinate measuring machines, these devices are usedin essential quality controls at multiple points throughout
production – from the prototype stage to the assembly
line, in two or three dimensions. As an expert in precisionengineering, ZEISS can also design and set up the ideal
inspection chain for every manufacturer.

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Sheet Stack

Rotor
Shaft

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Hairpins
Dimension &Coating Quality

Bending Design
Qualification
In the latest generation of e-motors, the current-carrying conductors inside
the stator are no longer wound from thin wires, but bent from solid copper
into hundreds of hairpins. These pins have individual shapes and differ whenit comes to the length, angles and cross-section of copper. Using hairpins
increases the amount of copper in the stator slots, which boosts efficiency.
This is why the dimensions and quality of the stator are so crucial.

Hairpin Measurement on CMM with

Hairpin Digitizing with the fringe light

Confocal Whitelight Sensor or Handheld

projection system ATOS Q

Laser Scanning

Each hairpin has a flexible structure
and is coated with a sensitive lacquer layer – these characteristics
create challenges for reliable tactile
inspection. An automated ZEISS
coordinate measuring machine,
equipped with confocal light or
laser triangulation optical sensor is
one option to accurately measure
the shape and lacquer thickness.
Another more manual, flexible tool
is a standalone ZEISS optical fringe
projection sensor or a ZEISS handheld laser scanner.

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The design of a hairpin is not simply
defined by a CAD model, but developed in many loops through theconfiguration of the bending parameters. It’s necessary to scan andproduce CAD models to evaluate
finished hairpins in relation to amaster pin. Fringe projection andlaser triangulation a high-resolution
point clouds of the hairpins. ZEISSReverse Engineering software canquickly turn these into high-quality
CAD models.

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Sheet Stack
Sheet Inspection

Assembly Quality

Single Sheet Inspection on ZEISSTactile Sheet Stack Measurement on

Contour Measurement with Confocal

Multisensor CMM

ZEISS Bridge-type Multisensor CMM

Whitelight Sensor on ZEISS Bridge-type

The sheet stack is built out of many single sheets, including crosssection slot
geometry for the hairpins, permanent magnet slots and the outer- and innerdiameter of the sheet stack assembly. Single 2D sheets provide the foundation
for constructing sheet stacks for rotors and stators. The single sheets are either
punched or laser cut from electrical steel sheets, and are less than 1mm thick.
The final sheet stacks require a large quantity of individual sheets.

CMM

The geometry of the 2D sheet defines
the dimensions of the final stator andpermanent magnet slots. This is why
it is so important to measure these
dimensions quickly and with highaccuracy. An ideal solution is to utilize
ZEISS multisensor technology, such as
2D cameras and confocal light sensors, to measure the flatness of eachindividual sheet. The flatness and thenon-existence of burrs are key factors
to ensure a sheet stack that is perfectly constructed and easy to assemble.

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During the assembly of the sheet stack, the positioning of the single sheets
for laser welding has a major impact on the geometry of the stator androtor slots, which are mated with the hairpins and the magnets. After welding, it is important to inspect the dimensions and positions of the slots, aswell as the height and diameters of the sheet stack. The contour features on
the assembly are also important for the process of inserting the hairpins andmagnets. ZEISS multisensor coordinate measuring machine can be combined with 2D cameras and whitelight confocal sensors to perform evenmore thorough inspections – for quality assurance you can rely on.

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Stator
Dimensional
Metrology

Weld Seam
Inspection

Assembly
Volume Analysis
The stator is responsible for the latest generation e-motor’s performance.
This component has the biggest potential to improve the performance,
power and efficiency of an e-motor. New raw materials and innovative
manufacturing technologies make quality assurance across all production
steps necessary to guarantee the safety, reliability and performance of the
e-motor.

Measurement of Contour andInspection for Defects in the Weld

Laser Scanning of the Stator –Dimensional features together on

Seam with ZEISS X-Ray Series

Handheld or Automatically on

one ZEISS CMM

During the stator assembly, theinsulation paper and hairpins areinserted into the slots of the sheet
stack and welded together. The
power supply connection points arealso welded. A number of characteristics require inspection, such as
the positions of the laser-welded
ends, to avoid short circuits in thestator. Flexible tactile and opticaltechnologies are necessary to get
accurate inspection results on positions and dimensions due to thevery flexible copper hairpins – a
ZEISS multisensor coordinate measuring machine.

48

ZEISS CMM

The hairpin ends must be laserwelded to allow current to flow
through the stator, generating theelectric field. In the weld process,remaining lacquer material on the
stripped pins or bad welding
parameters can cause porosity inthe weld seams – and result in poor
performance or the total breakdownof the e-motor. ZEISS computer
tomography (CT) technology can
detect, locate, classify and rate theinternal pores of the weld, finding
defective stators in a non-destructive
quality assurance process.

The outer boundary of the statoris crucial for mating the stator in the
e-motor housing. The connection
flange and shaft position require
inspection in relation with thetransmission. It is essential that thisdata be collected quickly and thoroughly. These requirements can beachieved by using ZEISS laser line
triangulation technology. This handheld, flexible option saves programming time to have measuring results
available quickly – or an automatedZEISS coordinate measuring machine
is ideal for higher quantities.

49Rotor & Shaft
Dimensional
Metrology

Shape & Contour
Measurement

Porosity Analysis

Rotor Dimensions Measuring on

Measurement of Tight Form

Cross section through the short circuit

ZEISS CMM with Long Stylus System

Characteristics on Shaft with ZEISS

ring for porosity analysis

The rotor is comprised of the shaft and the sheet stack with built-in
permanent magnets. Due to the high performance and speed of the e-motor, the rotor has very tight shape and location tolerances that require
inspection. The air gap between the rotor and the stator bore is one of themain parameters defining the e-motor’s performance and efficiency. It isalso critical with respect to the safety and reliability of the motor.

High Accuracy CMM

All dimensional features requiremeasurement technology that is
capable and accurate under the
influence of the rotor’s magnetic
field. The magnetic field can
influence measuring results
by deflecting the stylus or theinside of the probe. This makesa coordinate measuring machinethat can measure the tightest
tolerances with long and heavy
stylus systems essential – ZEISS
coordinate machines with active
scanning technology are ideal
for these requirements. Long
stylus extensions make it possible
to measure at each position of
the rotor, keeping the probe far
enough away from the strong
magnet field to ensure stable,
accurate results all around thestator.

50

The shaft inside electric and hybrid
vehicles requires very quick quality
inspection, especially when it comesto shape and position tolerances
due to the faster rotation speeds.
As shaft geometries change andtolerances narrow, a coordinate
measuring system makes it possible
to remain within these narrow
quantities while reducing throughput times and increasing predictability. A ZEISS coordinate measuringmachine equipped with a highly
accurate rotary table on air bearings
and a diamond stylus kit is ideal for
reliable results. Versatile coordinate
measuring machines can measure
shafts of all sizes.

Due to the increasing speeds in theelectric motors, the demands on thestrength and stability of the rotors
are significantly higher. In order toprevent the rotor from breaking
during operation, a certain porosity
level must not be exceeded. Computer tomography from ZEISS is
used to determine the size andnumber of pores in the rotor‘sshort-circuit ring. The recorded 3D
data are then analyzed and classified by ZEISS software using theporosity analysis.

51

53

Transmission
Electric vehicles have very different powertrains – with either a single-speed
or two-speed transmission instead of up to nine gears found in combustion
engines. The engine and transmission share a housing – reducing the number of components and weight, but not the quality requirements. A numberof measuring and inspection steps are needed to ensure top performance,
low wear and tear, and quiet operation. ZEISS produces all of these measurement tools, and consults with manufacturers to design ideal quality assurance systems.

5253

Transmission

High engine speeds of up to 20,000 rpm mean that the
gearwheels in the transmission must meet very small
geometric tolerances. These speeds are also demanding
for the shape and position tolerances of the rotor andgear shafts, especially where the bearings and gears arelocated. Having the electric motor and gearbox in thesame housing requires a very complex, yet lightweight
design, which involves precise machining steps on thecasted housing. The slightest deviations in the shape, size,
position or surface texture of these components canimpact the functionality and safety of the powertrain.
ZEISS has all of the measuring tools necessary to conduct
such sophisticated inspections. Computer tomography
can provide non-destructive detection of material defects
inside of a casting for a transmission housing. High-accuracy coordinate measuring machines have sensors for
dimensional, form and position tolerances as well as aroughness sensor for surface quality which can perform
precision measurements of the remaining transmission
components. In addition to developing groundbreaking
measuring technologies, ZEISS will continue to provide
advice and support to ensure customers can fully utilize
the equipment in their own production facilities.

54

Shaft

HousingGear

55

GearsDimensional
Accuracy

Complexity ofGear Parameters

Surface Quality
Quality assurance for gears is always an important challenge – in vehicles
equipped with injection combustion engines, e-motors or even hybrid
engines. The number of geared parts inside electric vehicles is far lower
than combustion engines. But high speeds combined with high torques
and the goal of having silent, energy-efficient transmissions makes quality
assurance increasingly important.

Gear Measurement on Rotary Table

Roughness Measurement on Gear

ZEISS GEAR PRO User Interface andwith ZEISS CMM and ZEISS CALYPSO

Tooth Flank and Evaluation withZEISS PiWeb Reporting Results Plot

Roughness Plot

Gears for electrical cars have very
tight tolerance requirements,
often just a few µm, to reducenoise and harshness at revolution
speeds of up to 20,000 rpm.
These tolerances require fastand high-precision inspection
equipment. A ZEISS coordinate
measuring machine with acontact probing system androtary table is the perfect solution
for gear metrology. Measure allgear parameters as well as theshape, size and location withjust one tool – for the highest
accuracy and flexibility.

56

Gears in new energy vehicles,
especially helical gears, areoften optimized in relation tonoise and efficiency by meansof gear flank modifications(e.g. crownings, reliefs, slope
modifications). Interactive, userfriendly gear metrology software
is a powerful, reliable tool tohandle the increasingly complex
requirements regarding noise,
vibration and harshness. ZEISS
software solutions offer the latest
reporting and data management
technology for a wide range ofapplications.

The e-motor is virtually silent
compared to combustion engines.
This is why it’s important to
reduce any other noise createdby shape, location and size
deviations in the components(shaft, bearing, gear), as well as
surface irregularities. Roughness
and waviness parameters also
play an important role. ZEISS
roughness and topography
sensors collect all the data – on
ZEISS coordinate measurement
machines and standalone highprecision systems.

57

Housing
Casting Inspection

Dimension & Location
Measurement

Surface & Contour
Quality
The electric motor and gearbox are usually located in the same housing.
This requires a very complex design, but should also be as light as possible
to increase the range of the electric vehicle. This leads to very small wall
thicknesses at the parts. They are usually cast from aluminum by die casting
and then machined by milling. The large number of machining steps requires the measurement of many different geometric features on the housing.

3D X-ray Scanning Data and Evaluation

Measurement of Housing with

Roughness & Countour Dataof Casting Defects in Cross SectionZEISS Tactile Scanning Technology

Acquisiting and Area Comparison ofa Gearbox Housing

The lightweight design of the battery electric or hybrid vehicles plays
an important role. Casted aluminum
housings have optimized shapes andthinner walls, for improved coolingbehavior and lighter weight. Thisextends the vehicle’s traveling range, but defects in the thinner structures in the casted walls can impact
the safety and cooling cycle of the
e-motor and transmission. ZEISS
X-ray technology effectively detects
variances, preventing defective
parts from going into machining
process.

58

Integrating the e-motor and transmission into a single housing createscomplex, interdependent geometries in the manufacturing process.
The shape, size and location ofthese components have tight tolerances because of the close functional proximity to other components
with high rotation speeds andtorque. ZEISS tactile active scanningcombined with flexible and stiffprobe systems and a rotary tablefulfills all inspection requirements.
ZEISS reporting and quality intelligence software evaluates and visualizes the smallest deviations.

Inspecting the geometry, surface
and contour of the housing is essential, but time-consuming. Measuring
all of these factors on a single
machine is much faster. A tactile
roughness sensor on a ZEISS coordinate measuring machine evaluates
all common surface parameters.
Optical confocal whitelight technology performs high-precision contour measurements, like chamfers
or radii on e.g. bores for bearings.
The ATOS ScanBox 4105 from GOM
is suitable for full-surface digitizationof the housing. The compact
measuring machine provides fully
automatic surface deviations
between the 3D actual coordinates
and the CAD data.
59

1 Meet.

2 Analyze.

3 Customize.
SCAN ME

Contact us
to booka consultation.

Identification of
specific quality
demands andsubsequent needs.

ZEISS teamcustomizes perfectfitting solution.

67

ZEISS eMobility Solutions

Battery Electronics Fuel cell system

Customize success

H₂

Coordinate
Measuring Machines

Microscopes

H₂

ZEISS offers microscopy solutions for a large range
of applications with excellent light, electron and
X-ray microscopes and various imaging systems.
For the development and quality assurance in thefield of e-mobility, ZEISS is able to provide customized
solutions to support the increasing demand for
microstructure analysis of energy materials andoptical inspection of smallest components withsolutions like:

Optical 3D Scanning

3D Measuring Machines

H₂

The broad portfolio of coordinate measuring machinesfrom ZEISS combines very precise tactile and opticalmeasurement with high measuring speed. Due to theincreasing meaning of precision in the e-mobility toinspect components with very tiny tolerances coordinate
measuring machines are becoming more and more
important. For this ZEISS offers solutions such as:

X-ray
H₂

With optical 3D scanning measurement technology fromZEISS, it is possible to digitize, measure and evaluate customer
requirements with high accuracy and high speed. Full-featured end of line quality control for e-motor and battery
applications can be achieved with fringe projection systems
or handheld laser triangulation scanner from ZEISS, like:For efficient quality control of different e-mobility components, GOM includes standardized optical measuring machines in its portfolio. The systems cover every process step,from programming to automated digitization, inspection
and reporting. For fully automated analyses of full-fielddeviations between actual 3D coordinates and CAD data,
GOM offers solutions such as:

ZEISS X-Ray Series reveals non-destructively what would
otherwise remain hidden from even the most watchfulof eyes. To overcome e-mobility related challenges, suchas safety and performance requirements, inspecting,measuring, and analyzing internal and external structuresof components is crucial. To solve these challenges
ZEISS offers X-ray solutions such as:• ATOS ScanBox for eMotors• ZEISS Smartzoom 5• ZEISS GeminiSEM 300• ZEISS LSM 900 Mat• ZEISS PRISMO• ZEISS CONTURA• ZEISS O-INSPECT• ZEISS T-SCAN Hawk
• ATOS Q• ATOS ScanBox• ZEISS METROTOM• ZEISS Xradia• ZEISS VoluMax

Power Electronics Transmission

Electric Motor

Mastering Quality Together

EN_60_021_0007IV Printed in Germany CZ-05/2023
Subject to changes in design and scope of delivery and due to ongoing technical development.
Printed on chlorine-free bleached paper. © Carl Zeiss Industrielle Messtechnik GmbHFor more information please visit:www.zeiss.com/emobilitysolutions