Helping You Address The New Electro-Mobility Challenge

Marposs continues to enhance and upgrade its measurement and inspection solutions to ensure complete monitoring of the production processes of EV components.

Marposs offers different solutions for the measurement and control of electric vehicles

For almost 70 years, Marposs has been working side by side with customers to guarantee quality control in the mass production processes. The wide range of technologies and products available, together with a worldwide presence, have made Marposs the ideal partner for OEMs, first and second tiers, as well as machine tool makers operating in the automotive industry.

In times of great changes, Marposs is taking up the challenge to stay a strong reference for the automotive market in the e-mobility era. The traditional product lines are integrated with new technologies to provide a mix of gauging, inspection and testing solutions that ensure the complete monitoring of the production process of the main electric vehicle (EV) components. Marposs offers a full range of solutions for the control and optimisation of the various manufacturing steps, the quality control of individual components, up to the final assembly operations and functional check of any assembled system.

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Traditional sensing, probing and in-process gauging solutions for process control during machining, turning, milling, and grinding operations are combined with thermographic analysis systems for process control during die-casting operations, and machine vision techniques to detect defects and porosity on machined sealing surfaces.

Consolidated techniques for monitoring of cutting and stamping operations are implemented in EV optic for process control in the production of rotors stack and stators’ sheet metal, or in the manufacturing of rigid battery cell housing.

Non-contact gauging products based on confocal or interferometric technologies are applied for process control in the production of metallic and non-metallic thin films, typically used in the manufacturing of anodes and cathodes, as well as in quality control of multi-layer pouch battery cover films.

Wide Range of Measurement Solutions

The battery trays provide the structural support of the car itself and must be leak proof to avoid the entry of water from the outside in all conditions.

The wide range of Opto and Flex machines for flexible shaft measurement is enriched with solutions that integrate different technologies to control a greater range of components; from traditional crank-, cam- and gear- shaft, up to rotor-shaft and complete rotors. The product range of optical gauges is enriched with non-contact measuring solutions dedicated to the analysis of shape and size on other critical components such as hairpins.

Automatic assembly operations of electro-mechanical components, such as battery chargers and power electronics are combined with measurement and test systems, up to the complete end-of-line functional verification.

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Thanks to collaborations with companies specialising in the sector, Marposs can today offer a complete range of products and applications dedicated to the execution of functional tests on electric motors and their components. The use of advanced techniques such as insulation tests with partial discharge method on stators, in association with more consolidated methodologies such as SURGE and HI-POT test, ensure the possibility of detecting also the presence of latent defects that could generate failures during use, and therefore guarantee compliance with the highest quality standards that are required for the use of electric motors in the automotive sector.

The synergistic contribution of other companies of the group, with specific skills in the automation sector, allows then to transfer these controls from laboratory environments to mass production, with the in-line integration of automatic machines for the execution of End-of-Line testing, both on rotors and on stators and finished electric motors.

Strong Experience in Leak Testing

Last but not least, the strong experience in leak testing applications, integrating different technologies, always guarantees the selection of the best solution for one of the most crucial controls in the manufacturing of all components of an electrical powertrain, from battery cells to modules and packs, up to electric motors, power electronics and related refrigeration circuits.

Performing of leak testing becomes a particularly strategic issue when it must be applied to battery components.

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The verification of the perfect sealing of the battery cells is absolutely fundamental to prevent dangerous leakages of liquid electrolyte, but also to ensure their efficient operation over time, due to the high sensitivity to humidity of the active components in the lithium-ion cells. The extremely low acceptable leakage allowed on the cells requires the use of vacuum chamber techniques, using helium as a tracer gas. Marposs offers a wide range of applications in this area, from fully automatic machines for 100% control in mass production lines, to manual stations for off-line verification of the components declared rejected in the in-line control.

The application of these techniques on the finished cells can be particularly complex due to their total sealing. For this purpose, Marposs has developed new leak testing methods, which do not require the addition of any tracer gas inside the cell.

The leakage check is then equally strategic at the battery pack level, in order to prevent the entry of water and other contaminants, which could cause the short circuit of high voltage components. In this case, although the leakage levels required to ensure compliance with IP specifications are normally higher than the reject limits imposed for the cells, the execution of the test is complicated by the large size of the component to be tested and by its high deformability.

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Marposs is able to offer a complete range of solutions and technologies to choose from, according to the test specifications requested by the customer. From solutions in air (pressure decay or mass flow), moving on to global testing techniques with helium in accumulation chamber or in the vacuum chamber. Helium sniffing solutions are instead used whenever it is necessary to accurately identify the leak point, as for example in repair stations.

Equally important, finally, is the verification of the perfect seal on all the different parts of the refrigeration circuits, on whose efficiency the optimal thermal management of all the components of the battery pack depends.

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