The IPH – Institute for Integrated Production Hannover and MFP Messtechnik & Fertigungstechnologie have launched a joint research initiative, “MotorInspector,” to improve the production quality of electric motors through automated measurement of the rotor-stator air gap.
Electric motors are central not only to electric vehicles—which now make up around 20% of new car registrations in Germany—but also to two-wheelers, ships, and aircraft. The gap between the rotor, the moving component of a motor, and the stator, the stationary part generating the magnetic field, is critical to performance. Uneven or inhomogeneous air gaps can reduce efficiency, cause vibrations, and shorten the motor’s service life.
The MotorInspector project seeks to automate this measurement process, which is currently performed manually. Over a two-year period, IPH will develop the automation concept while MFP provides the measurement technology, based on its “gapMaster” sensor. The sensor measures the air gap resistively, offering fast and robust readings, but has not yet been fully integrated into industrial production.
The project is particularly relevant for axial flux, or “disc,” motors, where even minor deviations in the air gap can drastically affect longevity. Researchers plan to use a robotic system guided by cameras or lasers to precisely insert the sensor into the motor, enabling in-line quality control without human intervention.
A prototype motor is currently being built for testing, and the project team is seeking collaboration with manufacturers of both axial and radial flux motors, including automotive groups, suppliers, start-ups, and research institutions. Contributions will be anonymized and integrated into the project’s development. Simon Pauka, the project manager, is the point of contact for interested parties.
The initiative is funded by the European Regional Development Fund (ERDF) and the state of Lower Saxony and represents part of Germany’s broader efforts to strengthen precision and reliability in electric motor production.