Systems and methods for non-destructively testing stator weld quality and epoxy thickness

A method for non-destructively testing an electric motor stator, the method comprising:

• obtaining pre-weld image data of the electric motor stator from one or more image sensors;
• determining one or more pre-weld characteristics of the electric motor stator based on the pre-weld image data;
• performing a welding process based on the one or more pre-weld characteristics, wherein the welding process includes welding hairpin wires and connectors of the electric motor stator;
• obtaining post-weld image data of the electric motor stator from the one or more image sensors in response to performing the welding process;
• obtaining epoxy image data of the electric motor stator from the one or more image sensors in response to obtaining the post-weld image data;
• performing a difference-based image processing routine based on the post-weld image data and the epoxy image data to generate a digital twin of the electric motor stator;
• and
• determining one or more epoxy characteristics of the electric motor stator based on the digital twin.

A system for non-destructively testing an electric motor stator, the system comprising:

• one or more processors and one or more nontransitory computer-readable mediums comprising instructions that are executable by the one or more processors, wherein the instructions include:
• obtaining pre-weld image data of the electric motor stator from one or more image sensors;
• determining one or more pre-weld characteristics of the electric motor stator based on the pre-weld image data;
• performing a welding process based on the one or more pre-weld characteristics, wherein the welding process includes welding hairpin wires and connectors of the electric motor stator;
• obtaining post-weld image data of the electric motor stator in response to performing the welding process;
• obtaining epoxy image data of the electric motor stator in response to obtaining the post-weld image data;
• performing a difference-based image processing routine based on the post-weld image data and the epoxy image data to generate a digital twin of the electric motor stator;
• and
• determining one or more epoxy characteristics of the electric motor stator based on the digital twin, wherein the one or more epoxy characteristics include an epoxy thickness, an epoxy distribution, or a combination thereof.