Transforming innovation on Metrology

Transforming innovation on Metrology
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One prominent change in the automobile industry that is continuously occurring is the emergence of electric vehicles (EV), which has been receiving attention and support from several industrial sectors. In the present, the world is encountering energy challenges, significantly affecting global warming. The transition from using fossil fuels to energy sources is happening at a rapid pace, having the potential to achieve sustainability and enhanced energy efficiency. A part of the change involves using electric vehicles (EV) that has been meticulously manufactured and engineered to achieve top-tier quality and efficiency. Throughout the manufacturing of EVs, measuring technology and quality control play an essential role in the inspection process, ensuring that the manufactured vehicles adhere to the highest standards of quality and safety for users.

Transforming innovation on Metrology

Measurement and regulation of quality in EVs encompass not only product and workpiece quality inspection, but also utilization of modern technology to control manufacturing processes ensuring efficiency and consistency in accordance with the highest quality standards. It also minimizes errors within manufacturing processes and perpetually upholding established quality benchmarks.

               This article contains explanation of technology employed for measurement and quality regulation in manufacturing electric vehicles (EV), including the significance of technology utilization in manufacturing cars to achieve safety and build a strong foundation for future advancements. Additionally, this article also explores the importance of maintaining the surroundings and sustainability in the manufacturing processes of EVs, which stand as the primary influencing factor in decision-making process of both manufacturers and consumers.

Importance of Measurement of Electric Vehicles (EV)

Transforming innovation on Metrology

Measurement in the manufacture of electric vehicles (EV) holds a paramount importance in regulation of production, as this affects the quality and reliability of the product, including safety and efficiency of the system, which is highly significant.

               Quality of the product, In the manufacture of electric vehicles (EV), quality of the product is highly important as the product with top-tier quality guarantees satisfaction from consumers and minimizes risks in safety terms. In addition, it serves to enhance the image of the manufacturing company. Measurement plays an essential role in regulation and maintenance of EV quality in several procedures in the manufacturing processes. This spans from quality testing and inspection during the vehicle production to ensure the adherence of rigorous quality standards, including endurance of materials utilized in manufacturing various components and conducting tests on the safety systems within the vehicle. These include but are not limited to the braking system, protection mechanisms, safety features in the electrical connection, and examination of efficiency of other electrical systems. 

Transforming innovation on Metrology

Improvement of Manufacturing Efficiency Measurement serves as a pivotal tool in the improvement of quality and efficiency in processes of manufacture, inspection and amendment of potential errors. Its rapid and accurate production results in higher production efficiency and reduction of errors in manufacturing process. Moreover, measurement serves as a protection to minimize the potential issues in manufactured vehicles, including streamlining manufacturing steps through specifications, thereby reducing the cost and increasing efficiency. In addition, the data derived from measurement procedure facilitates the analysis of manufacturing processes, enhancing efficiency.

               Conserving Resources Conservation of resources serves as a pivotal vision across diverse industries, including the electric vehicle (EV) sector. Measurement plays an essential role in this vision by tracking the utilization of materials, identifying unused and recyclable elements, thereby reducing material losses and minimizing extraneous procedures in the manufacturing process. This includes the inspection of energy consumption and the energy density in manufacturing procedures, enabling an efficient use of energy resources and reducing potential inefficiencies. In addition, measurement also opens doors for meticulous amendments of various stages throughout the manufacturing process, reinforcing environmentally practices, ensuring efficient utilization of resources. This, in turn, enhances the sustainability and reliability of electric vehicles in the market.

               Energy Efficiency, The accurate measurement of electric vehicles (CV) holds a paramount importance in facilitating manufacturers and engineers to amend and develop the internal systems of vehicles through detailed analysis of energy consumption in each component of the car, for instance, battery charging, movement, and operation of energy control system. This extends to evaluating whether the designed and modified energy systems meet the established standards, ensuring higher energy efficiency and reliability. In addition, measurement also aids in identification of novel technology with the ability to increase the energy efficiency of electric vehicles (EV) and surroundings by utilizing technology consuming less energy whilst maintaining the high efficiency.

               Credibility of Consumers, In the electric vehicle (EV) industry, consumer trust and credibility play an essential role in shaping the brand image of the car and has a significant impact on the perception consumers hold towards the manufacturing company. Consumers usually hold a notion of the product quality positively correlating with credibility; manufactured electric vehicles (EV) exhibiting high quality and adhering the established standards instill confidence among the consumers in purchasing decisions and subsequent utilization. In addition, reliability of safety systems achieved through continuous testing and improvement plays a crucial role in enhancing consumer confidence on the safety and reliability of the product.

Measuring technology used in the production of EV

Vision Measuring System is a highly efficient machine designed for measurement of dimensions and positions of small-sized materials, usually utilized in tasks requiring high speed and accuracy, such as inspection of chip quality and measuring microscope – a specialized camera designed for meticulous measurement and inspection of details in small materials. This technology is particularly employed in works demanding high resolution, such as examination of quality of boding or small abrasions in chips. In addition, it is utilized to inspect the contamination of lithium-ion batteries, an important component of power control unit (PCU) in electric vehicles. PCU serves to control and manage transmission of electrical energy across various components of the energy system, including batteries, electric motors, and other machinery, facilitating high functioning of electric vehicles by enabling adjustment of electrical capacity in each component according to the specific requirements.

Transforming innovation on Metrology

               In addition, the vision measurement system has been employed for measurement and inspection of motor core, a pivotal element in energy conversion, from electrical energy to kinetic energy. These motor cores are constructed from workpieces that are milled into grooves or arranged along an axis, in which measurement and inspection of motor core serve as a crucial procedure in manufacturing and coordination of electric vehicle system (EV). The vision measurement system with a touch signal probe facilitates accurate measurement of the grooved parts.

Transforming innovation on Metrology

CNC Coordinate Measuring Machine The measuring machine employed in 3D measurement and inspection of dimensions and shape of materials with intricate details encompasses computer control (CNC), enabling automated operations in accordance with the information received from computer system. This is utilized in measuring the aluminum PCU cover serving as a protective shield for the PCU to safeguard the internal components from the impact of weather conditions, dust, and other factors that may compromise the efficiency and durability of the material.

               Roundness Measuring Machine and Cylindricity Measuring Instrument is a measuring machine employed in precision measurement of spherical and tubular or cylindrical shapes, which is subsequently utilized in measuring the diameter or rotor outside. This serves as an electricity generator when received adequate energy, resulting in rotation for power transmission to the vehicle and stator inside diameter.

Laser Scan Micrometer is a measuring machine utilized in measurement of materials by using laser scanning technology to derive accurate measurement values with speed and precision. This process involves using laser to scan through the materials slated for measurement, facilitated by a system that conducts inspection and recording of details in the form of charts or graphs to be used in measuring external diameter of spools used in rotors.

Litematic Machine A machine with high precision utilized in measurement of thickness or height of workpiece susceptible to measuring force. With the measuring force of just 0.01 newton, it is particularly compatible for accurately measuring workpiece prone to shape or component alterations. This machine is utilized in measuring lithium-ion batteries that have control on the thickness of CP separator, an element that insulates the positive and negative anodes. This precision is paramount in the production of lithium-ion batteries, as a lower measured force reduces the risk of material indentation, minimizing potential hazards such as explosion and sparks. 

Transforming innovation on Metrology

UMAP Vision System is a microscopic form measurement system with a low force probe of 1 μN  that uses detection technology, facilitating in measurement of a variety of workpieces, including ones susceptible to shape alterations with product group stylus with a minimum diameter of 15 µm, aiding the measurement of exposure of surface with a microscope. This highly meets the demands in terms of measuring dimensions and shape, including corner radius, distance, and corner. It integrates technology for measuring both shape and surface roughness within a single device (Formtracer), a combination of high-precision measurement, analysis of surface roughness, dimensional shape analysis complemented by the computer system CNC, enabling in measuring separator sheets or workpieces designed to prevent contact with hydrogen and oxygen. These separator sheets act as barriers between positive and negative layers in fuel cells.

Micrometer is a high-precision measuring machine with the ability to measure the width, length, thickness, and level difference of workpieces. It is a machine that offers high resolution and accurate measurement readings, which is utilized in measurement of a comprehensive range of wiring harness in electric vehicles (EV).

Surface Roughness Tester A machine employed in testing the roughness of material surface on a variety of workpieces to inspect and control quality of production. It is utilized in machining works or metalworking laboratories, which can be used in measuring metal terminals within charging plug of electric vehicle (EV).

Article by: Sumipol Corporation Ltd. & MEGA Tech