AIT Hairpin Inspection

Hairpin technology has become the industry standard for manufacturing high-performance traction motors in electric mobility applications. Instead of conventionally wound copper wire, precisely formed rectangular copper conductors are used. This design enables higher power density, improved efficiency, reduced energy losses, and superior thermal conductivity. However, these advantages also place exceptionally high demands on the quality of each individual hairpin.

The AIT Hairpin Inspection system has been specifically developed for the requirements of e-mobility motor production.

During the manufacturing process – before the actual winding and assembly stages – every single hairpin is reliably inspected for coating residues and dimensional accuracy. This ensures that only defect-free components proceed to subsequent production steps, preventing costly downstream quality issues.

The optical inspection process features a comprehensive 360-degree quality control system that captures all relevant characteristics around the entire hairpin geometry. A powerful PC-based inspection platform, combined with four high-resolution cameras and optimized illumination, delivers highly repeatable measurement results even at high production speeds.

The system also compensates for wire vibrations during feeding, ensuring stable and precise inspection performance under demanding high-speed operating conditions.

With AIT Hairpin Inspection, manufacturers establish the foundation for efficient, stable, and future-proof production of high-performance electric motors.