Technical Case Studies
Discover how our high-precision metrology solutions solve complex engineering challenges across the globe.
EV Motor Housing Coaxiality Audit
Solving high-speed thermal whine in triple-motor enthusiast vehicles through micron-level boresight alignment and structural stability analysis.
The Challenge
A Tier-1 manufacturer of electric drive units (EDUs) for a high-performance supercar was struggling with a "ghost noise" at 18,000 RPM. Traditional inspection showed the bearing bores were within size tolerance, but the dynamic interaction between the primary motor shaft and the reduction gear integrated housing was causing micro-vibrations. The complexity of the casting, with over 15 interleaved datums and thin-walled thermal jackets, made standard CMM alignment strategies unstable and non-repeatable across different inspection shifts. The project was at a standstill, risking a multi-million dollar production delay.
The Result
Service Metrology engineers performed a deep-dive "Metrological Root Cause Analysis." We discovered that the casting was subtly flexing during the clamping process due to internal residual stresses. We redesigned the inspection fixture to use a "3-point kinematic nest" and implemented a custom Calypso scanning template that utilized 4th-axis rotary table synchronization. This allowed us to measure the coaxiality of the bores in a single continuous spiral scan, capturing the circularity, cylindricity, and true spatial axis in one pass. We identified a 0.007mm axis deviation that only occurred after the second stage of machining. By optimizing the tool path sequence, we eliminated the NVH (Noise, Vibration, Harshness) issue entirely, resulting in a 100% pass rate for the drivetrain assembly.
EV Battery Interconnect Validation
Non-destructive verification of internal laser welds and cell alignment within a sealed battery module.
The Challenge
Modern EV battery modules use hundreds of laser-welded interconnects between cells. Traditional testing requires destructive cross-sectioning, which only captures a tiny sample. The client needed a way to verify the weld penetration and porosity of 100% of the interconnects in the final sealed assembly.
The Result
By deploying a high-energy Industrial CT (Computed Tomography) solution, we enabled full volumetric inspection of the module. Our automated voxel analysis software identifies weld voids and depth-of-fusion violations without opening the pack. This improved throughput by 500% and provided an absolute digital record of every single electrical junction.
Fusion Reactor Spatial Alignment
Large-volume component alignment with sub-millimeter precision across a 100-meter facility.
The Challenge
In large-scale engineering like nuclear fusion or satellite assembly, the biggest challenge is maintaining a unified coordinate system across massive structures. The client needed to align vacuum vessel segments weighing 400 tons to within 0.2mm of their theoretical positions relative to the reactor's magnetic center-line.
The Result
We deployed a networked Leica Laser Tracker system utilizing Spatial Analyzer (SA) software. By implementing a Unified Spatial Metrology Network (USMN), we achieved a global uncertainty of 0.15mm across the entire 120-meter assembly hall. This ensured that the vessel segments mated perfectly on the first attempt, preventing months of costly rework.
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