The new energy motor industry is embracing a wave of intelligent upgrades. Traditional manual operations is difficult to meet millimeter-level positioning demands, while challenges such as highly reflective surfaces, multi-size compatibility, and foreign object detection remain bottlenecks.
Transfer Technology’s high-precision 3D vision solution has enabled a leading new energy motor manufacturer to achieve fully automated stator core loading and unloading—ushering in a new era of “zero-error” smart manufacturing.
01 Project Solution: 3D Vision + KUKA Robot
Epic Eye Laser L 3D Camera – High-precision laser scanning with strong ambient light resistance, IP65 protection, and anti-vibration design to withstand dust, oil, and machine vibrations.
Intelligent Software Platform – Real-time motion path planning, compatible with multiple product models.
KUKA Robot Arm – Accurate gripping of both stator cores and finished stators.
Camera scans the stator core to generate a high-precision point cloud.
System detects foreign objects in slots and locates the crown end.
Robot loads qualified stator cores and automatically sorts out defective ones.
Finished stators are stacked layer-by-layer, with automatic tray switching.
02 Overcoming Challenges: Four Key Technical Breakthroughs
Millimeter-Level Accuracy Challenges
- Stator core stacking tolerance is only 0.5 mm, requiring 100% steel wire height inspection.
- Solution: Proprietary phase compensation algorithm reduces point cloud fluctuations by 50%.
Reflective surfaces interfere with traditional vision systems.
Solution: Blue structured light technology resists up to 120,000 lux ambient light, achieving >99% complete point clouds.
Compatible with 6 different stator sizes.
Solution: Deep-learning-based template matching algorithm enables rapid changeovers with modular switchover design.
Stable Performance in Harsh Environments
Factory vibrations, oil contamination, and temperature/humidity variations.
Solution: IP65 protection + custom anti-vibration mounts ensure 24/7 stable operation.
Efficiency Gains: ≤5 seconds per cycle at a single station, reduced labor demand—only two operators needed for full-line changeovers.
Quality Assurance: ±1 mm gripping accuracy, product yield rate improved to 99.99%.
- Flexible Expansion: Rapid adaptation for new product types.
Transfer Technology’s 3D vision solutions have been deployed at scale across automotive, home appliance, and pharmaceutical industries. This new energy motor project proves once again: “Precision is the foundation of smart manufacturing.”
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