Case Study | Precision Within Millimeters: How 3D Vision Redefines New Standards for New Energy Motor Smart Manufacturing

The new energy motor industry is undergoing comprehensive intelligent upgrading. Traditional manual operation can no longer meet strict millimeter-level positioning demands. Meanwhile, core industrial bottlenecks including highly reflective metal surfaces, multi-model compatibility, and in-situ foreign object detection severely restrict production stability and yield. Leveraging high-precision 3D vision technology, Transfer Technology delivers a fully automated loading and unloading solution for a leading new energy motor manufacturer, empowering zero-error intelligent motor manufacturing.

01Project Solution: 3D Vision + Robotic Collaboration

Epic Eye Laser L 3D Industrial Camera

Features high-precision laser scanning and powerful anti-interference capability against ambient light. Adopting IP65 protection grade and professional anti-vibration structure, it stably operates in dusty, oily and vibration-prone workshop environments.

Intelligent Vision Software Platform

Supports real-time robotic trajectory planning and flexible adaptation for multiple motor core models to meet mixed-production demands.

KUKA Industrial Robot

Executes stable and precise gripping and handling for iron cores and finished motor stators.

Automated Workflow:

1.The 3D camera scans iron cores to generate high-density, high-precision full-scene point cloud data;

2.The system detects slot foreign objects and accurately locates the crown end of iron cores;

3.The robot picks up qualified iron cores for automated loading, while defective workpieces are intelligently sorted out;

4.Finished stators are stacked layer by layer, with blister trays automatically switched to realize cyclic unmanned production.

02Technical Breakthroughs: Solving Four Core Industrial Pain Points

Millimeter-Level Ultra-Tight Tolerance Control

The lamination thickness tolerance of motor iron cores is only 0.5 mm, requiring 100% full inspection of wire core height consistency. Traditional vision solutions struggle with tiny dimensional fluctuations. Transfer Technology’s self-developed phase compensation algorithm reduces point cloud fluctuation by 50%, achieving ultra-stable high-precision detection.

High-Reflection Surface Imaging Suppression

Metallic iron core surfaces produce strong reflection, causing noise and missing point clouds for conventional vision systems. Equipped with blue fringe structured light technology, the camera delivers outstanding anti-light-interference performance up to 120,000 lux, ensuring a point cloud completeness rate above 99% for highly reflective workpieces.

Multi-Specification Flexible Production Adaptation

The production line needs to handle 6 types of iron core specifications with frequent model switching. Powered by deep learning template matching algorithms and modular switching design, the system supports rapid model replacement and zero-delay adaptation for multi-variety production.

Harsh Workshop Environment Stability

On-site equipment vibration, surface oil contamination, and temperature & humidity fluctuations easily affect imaging stability. With IP65 industrial protection and customized anti-vibration brackets, the whole system supports 7×24-hour continuous trouble-free operation, adapting to complex workshop conditions.

03Project Value: Dual Upgrade in Production Efficiency & Product Quality

Higher Operational Efficiency

The single-station cycle time is controlled within 5 seconds per cycle, realizing efficient automated production. The solution greatly cuts manual labor costs, requiring only 2 operators to complete full production line model switching and daily maintenance.

Stable Ultra-High Yield

The system achieves a gripping positioning accuracy of ±1 mm. Standardized visual inspection and robotic handling eliminate manual errors and workpiece damage, raising the product qualified rate to 99.99%.

Strong Flexible Expansion Capacity

The intelligent algorithm platform supports rapid calibration and adaptation for newly launched product models, reserving long-term iterative upgrade space for production lines.

Transfer Technology’s 3D vision solutions have been widely deployed in automotive, home appliance, pharmaceutical and other industries. This new energy motor project once again verifies that precision is the cornerstone of intelligent manufacturing. With millimeter-level recognition accuracy and second-level ultra-fast cycle efficiency, 3D vision technology helps traditional manufacturing thoroughly upgrade to high-precision, high-stability and high-flexibility smart production.