E11015(2)Introduction to Precision Measuring Instrument Solutions

PRECISION IS OUR PROFESSION

Introduction to Precision Measuring Instrument Solutions—Electric Vehicle xEV Measurement —Mitutoyo Precision Measuring Instruments That Support
Power Control Unit
(PCU)
IGBT (Insulated Gate Bipolar Transistor)
This is a power transistor which is a major component in an inverter.
An inverter is an assembly of semiconductor components.
A vision measuring system is effective for high-speed inspectionof minute parts such as chip and bonding wires, and a measuring
microscope is effective at checking chip bonding solder for cracks.

PCU Cover
A CNC coordinate measuring machine that allows automatic
contact measurement of complicated 3D form is used for thePCU cover, which is an aluminum die casting.

Motor
Motor Core
The use of a vision measuring system equipped with a touch signal probe
allows effective measurement both of discrete pressed components before
lamination, and laminated parts. The vision measurement mode is available
for thin, flat, discrete components before lamination and the touch probe
mode is available for 3D evaluation of twist and displacement of laminatedparts. A roundness/cylindricity measuring instrument is also effective formeasurement of rotor outside diameter and stator inside diameter.

Coil
A laser scan micrometer that allows high speed, highresolution measurement is effective at measuring the outside
diameter of coils used for rotors.

2

Development and Production of Electric Vehicles xEV
Battery
Lithium-ion Battery
Control over the thickness of the separators that insulate the positive electrode fromthe negative electrode is absolutely essential for the manufacturing process of lithiumion batteries (which are subject to explosion or fire risk). The high-accuracy length
measuring machine VL-50 is best suited to this thickness measurement thanks to a low
measuring force that minimizes distortion of the material. Also, a measuring microscopeis used to check for any contamination inside a laminate-type lithium-ion battery.

Fuel-cell Separator
The fuel-cell separator is molded to incorporate flow
channels for gas diffusion. The minute-form measuringsystem UMAP that has a minimum probe-ball diameter of
15μm and an ultra-low measuring force of 1μN (minimum)
has achieved high-reliability measurement of features
such as corner radius, pitch, and angle. For wall-thickness
measurement, a Formtracer is ideal since it allows
continuous measurement of top and bottom faces usingwith a dual-side conical stylus.

Wiring Harness

Battery Charger/Charger PlugA specialized micrometers is used for measuring theheight of crimped contacts on wiring harnesses.

In-vehicle Battery Charger
An in-vehicle battery charger includes various parts such as acover, connector, housing, and relay. Mitutoyo's product lineup- including coordinate measuring machines, vision measuringmachines, form measuring instruments, and others - fully cover
the many types of measurement required on these components..

Quick Charger
In order to improve efficiency of the metal terminals in a socket,
measurement by a surface roughness tester is effective.

3Solutions to Measurement for Electric Vehicle xEV
Mitutoyo offers solutions to measurement of a wide varietyof electric vehicles from research and development topreproduction and mass production.

Classification of Electric Vehicle xEV
EV: Electric Vehicle
Battery

HEV: Hybrid Electric Vehicle/
PHEV: Plug-in Hybrid Electric Vehicle

Motor

Gasoline + Battery
Engine + Motor

Electric Vehicle xEVFCEV: Fuel-Cell Electric Vehicle
Hydrogen + Battery
MotorEnergy supply
Power source4Precision Measuring Instruments That Support Development and Production of Electric Vehicle xEV
The table below matches Mitutoyo's precision measuring instruments to various applications.
Form
Coordinate CNC vision Minute
Measuring Precisionform
measuring microscopemeasuring measuring measuring
sensorsystemmachinesystemsystemComponents

Lithiumion
Battery
BatteryMotorApplications

Cover part dimension
measurement, surface texture✔

Battery case dimension
measurement, surface texture✔

✔
✔

✔

✔

✔

✔

✔

✔

✔

✔

Separator thickness/width✔

Section dimension measurement/observation (presence or absenceof contamination)
Molded part dimension/
Hydrogen/ form measurement
oxygenMolded part thickness
fuel-cell measurement
separator
Mold contour measurement

Motor
Core

Hardness Measuring
testing
toolmachine

Unlaminated pressed-partdimension measurement
Laminated-part dimension, various
geometric tolerance measurement

✔
✔
✔
✔

✔

Rotational axis runout✔

Commutator Peripheral adjacent gap✔

Housing✔

Bearing coaxiality✔

✔

✔

✔

✔

✔

✔
✔

✔

✔

✔

✔

Outside diameter✔

✔

Coil
Post-wound form check

Power IGBT *Control
Unit(PCU)

Various dimensions ofpower modules
Various dimensions ofsemiconductor circuitry
Soldered part crack
inspection✔
✔

Various dimensions of aluminum
cabinet, surface texture
Various dimensions ofaluminum cabinet
In-vehicle
Various dimensions ofBatterypressed parts
ChargerConnector pin squareness/roughness
Battery
charger
Various dimensions ofsockets
Quick
Terminal surface texture
Charger
Various dimensions ofpanels✔

✔

✔

✔

✔

✔
✔

Bonding wire height

Inverterhousing✔

✔
✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔
✔

✔

✔

Height of crimp contact✔

Wiring Harness
Core wire length/diameter✔

✔

✔

✔
* Insulated Gate Bipolar Transistor

52312(JP3), Printed in Japan

Coordinate Measuring Machines

Vision Measuring Systems

Form Measurement

Optical Measuring

Whatever your challenges are, Mitutoyo
supports you from start to finish.
Mitutoyo is not only a manufacturer of top quality
measuring products but one that also offers qualified
support for the lifetime of the equipment, backed up
by comprehensive services that ensure your staff canmake the very best use of the investment.
Sensor Systems

Test Equipment

Digital Scale and DRO Systems

Small Tool Instruments
and Data Management

Apart from the basics of calibration and repair,
Mitutoyo offers product and metrology training,as well as IT support for the sophisticated software
used in modern measuring technology. We can also
design, build, test and deliver measuring solutions
and even, if deemed cost-effective, take your criticalmeasurement challenges in-house on a sub-contract
basis.

Find additional product literatureand our product catalogue
https://www.mitutoyo.co.jp/global.html
Mitutoyo Corporation
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All product information contained in this brochure is current as of December 2023.

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