Tube Inspection Software Enhances EV Component Manufacturing

Hexagon has released an updated version of its BendingStudio XT software, designed to improve inspection efficiency and process control in tube and wire manufacturing. The update combines high-speed optical measurement with portable 3D scanning, supporting faster cycle times and enhanced quality assurance, particularly in electric vehicle (EV) component production.

Optical Inspection for High-Throughput Production
At the core of the system is Hexagon’s TubeInspect platform, an automated optical inspection cell engineered for non-contact measurement directly on the shopfloor. The system delivers dimensional verification within seconds, enabling manufacturers to maintain tight tolerances under variable conditions such as temperature fluctuations, dust, and oil exposure.

TubeInspect incorporates temperature compensation and ISO 17025-certified calibration, ensuring repeatable accuracy across production environments. The system supports simultaneous measurement of multiple identical parts, allowing batch inspection without interrupting production flow.

Real-Time Feedback and Process Integration
The updated BendingStudio XT software connects inspection data directly with production systems, enabling real-time feedback to tube bending machines. This closed-loop approach allows automatic correction of deviations, reducing scrap rates and improving product consistency.

Operators receive immediate pass/fail feedback through a simplified interface, minimizing the need for specialized metrology expertise. This integration supports a more efficient digital supply chain by linking measurement data with manufacturing execution processes.

EV-Specific Capabilities for Hairpin Components
The software introduces dedicated correction reporting for electric motor hairpins, which are critical components in EV drivetrains. These geometries require high precision due to their impact on motor efficiency and performance.

By providing targeted analysis and correction data, the system supports tighter quality control in EV manufacturing, where component tolerances directly influence electrical performance and thermal behavior.

Expanding Measurement with Handheld 3D Scanners
The update extends compatibility to handheld 3D scanning systems, enabling flexible measurement beyond fixed inspection cells. Integration with the ATLASCAN Pro provides an entry-level solution for smaller manufacturers or project-based inspection tasks, reducing the need for large capital investments.

For larger components such as industrial pipework or exhaust systems, the HYPERSCAN scanner enables accurate measurement of parts up to 5.5 meters in length. These portable solutions allow operators to measure components in situ, improving efficiency in complex or space-constrained environments.

CAD Integration and Complex Geometry Verification
Enhanced CAD integration allows direct comparison of measured components with design data. A new CAD adapter supports rectangular profiles, including busbars used in electric mobility systems, enabling precise verification of position and orientation.

This functionality reduces setup time and supports traceability from design to finished part, ensuring compliance with stringent quality requirements in automotive and industrial applications.

Relevance for Digital Manufacturing Systems
The updated BendingStudio XT reflects broader trends toward integrated inspection and manufacturing systems. By combining automated measurement, real-time feedback, and flexible scanning technologies, the platform supports more efficient and adaptive production processes.

These capabilities are increasingly important in modern manufacturing environments, where data-driven quality control and process optimization are essential for maintaining competitiveness and meeting evolving industry requirements.

Edited by Romila DSilva, Induportals editor, with AI assistance.