Development of an electronic gap measurement system for electric motors and generators with automation interface

In the course of the energy transition and electromobility, electric machines are becoming increasingly important. A key design parameter is the air gap between the rotor and stator, which has a significant influence on efficiency, torque and smooth running. Manufacturing tolerances and assembly conditions have a major impact on this sensitive variable, making precise quality control through air gap measurement indispensable in electric motor production. 

Currently, measurement is carried out manually using mechanical test equipment such as feeler gauges, measuring wedges and ball gauges - time-consuming, prone to errors and only able to cover specific measurement points. The MotorInspector research project is therefore developing an automated measurement method that enables reproducible and error-free air gap measurement. The basis is the resistive measuring method developed and patented by the company MFP with the “gapMaster”, which allows fast and material-independent detection that can record the entire gap profile. 

The IPH is developing an automation solution for this, with which the measurement can be carried out precisely, safely and efficiently with robot support. In addition to exact sensor positioning, the focus is also on automated calibration and comprehensive data processing. MotorInspector thus provides the basis for fully automated electric motor production and makes an important contribution to quality assurance in the industry.