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Hairpin motor welding

Hairpin motor welding

Electric vehicle motors are an important part directly related to vehicle performance and energy efficiency. The hairpin-shaped design provides higher torque and output compared to ROUND WIRE as a solution to reduce interference. Since copper bars with both ends removed must be wound and inserted in a U-shape, precision system design is essential.

Key features
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Hairpin motor welding

Features

STRIPPING

Pulsed energy is used to remove the enamel insulation layer. Color deformation due to thermal effects does not cause structural changes in copper, but it can cause peripheral contamination and malfunction due to Burr. Lasers perform ablation and cleaning 80% faster than mechanical methods.

Marking

Tracking marks, including text, logos, barcodes, and serial numbers, can be finely engraved on the stator surface. Production quality can be properly controlled by tracking raw materials and finished products with permanent laser engraving.

WELDING

The protruding part of the hairpin inserted into the stator is welded by Pair. In order to prevent weld defects caused by vehicle vibration, it is necessary to reduce external changes and warpage due to melting. Laser systems with precise targeting and flexible position changes can implement excellent welding methods such as wobble and cross machining.

STRIPPING

Pulsed energy is used to remove the enamel insulation layer. Color deformation due to thermal effects does not cause structural changes in copper, but it can cause peripheral contamination and malfunction due to Burr. Lasers perform ablation and cleaning 80% faster than mechanical methods.

Marking

Tracking marks, including text, logos, barcodes, and serial numbers, can be finely engraved on the stator surface. Production quality can be properly controlled by tracking raw materials and finished products with permanent laser engraving.

WELDING

The protruding part of the hairpin inserted into the stator is welded by Pair. In order to prevent weld defects caused by vehicle vibration, it is necessary to reduce external changes and warpage due to melting. Laser systems with precise targeting and flexible position changes can implement excellent welding methods such as wobble and cross machining.

It maximizes power density without residual coating on hairpins.

Power is transmitted through a hairpin copper wire bent 180° and assembled on the stator. Each hairpin is welded to the hairpin next to it, and the insulation at the end must be removed cleanly to improve weld quality. Of course, the integrity of copper must be maintained. The laser removes various insulating coatings such as PAI, PEEK, and PAI+FEP from various angles with a fast cycle.

WHY K2?

Obviously, lasers are very powerful. However, full utilization is not possible without correct system design and process design. We focus exclusively on laser automation systems and have accumulated advanced technology and successful experience for many years. Please leave your laser processing solutions to K2 Laser System, a laser specialist company.

persons

We respect the existence and value of all employees and aim for an inclusive culture where they can enjoy themselves together.

mission

With a customer-centered management philosophy, we will always put the interests of our customers first and meet their expectations.

quality

We will create a system that produces value over a long period of time with a configuration that has been proven to be highly durable.

techs

We enhance resource efficiency by adding innovation to laser processes without consumables and by-products.

3kW

POWER

MULTI

ANGLE

Hairpin motor welding

Core Technology

OCT

For excellent processing accuracy, hairpin errors generated during the entire process must be precisely measured. OCT is a proven method for detecting the height and position of hairpin pairs. If the allowable tolerances are exceeded, welding is not performed and unnecessary consumption of materials is prevented. Furthermore, by measuring the outline of the solidified weld bead with OCT, it is possible to automatically detect defects in the bead and reduce conductivity degradation.

SMART Alignment

To achieve full weld quality while minimizing processing time, hairpins must be properly aligned. K2's Hairpin welding system measures the shape and relative position of the hairpin before processing is performed to check for gaps, gaps, and inclinations.

Superb quality

Various core capabilities must be fully implemented in laser peeling and laser welding equipment for hairpin motors, such as jig fixing systems, pore suppression technology, and pollution minimization structures. Join K2Laser, a laser expert

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Core Technology

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