Hair-pin laser welding drives electromobility
In high-performance electric cars, the stationary part of the motor consists of many copper wires shaped like hairpins. Short-pulse laser technology has proven to be the perfect tool to connect the hairpins with high quality and reliability. The stripping of the wire coating and the geometry inspection are also performed with lasers.
This is a Copper flat wire in typical hairpin geometry. It is approx. 30 cm high.
These hairpins are inserted into the stator stack - the stationary part of the motor.
The hairpins are pre-assembled in an assembly nest. The insertion process is limited by overlaps in the winding geometry.
To form a continuous winding scheme, the hairpin ends are electrically contacted.
Using a laser, the hairpin ends are partially melted and joined.
An optimal laser welding process is marked by homogenous weld geometries as well as minimal thermal input.
A very warm thank you to all the companies and institutes that made this publication possible.
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Text and research: Wenko Süptitz, SPECTARIS
Graphic: Schwochow Visual Stories GmbH
Scrollytelling: Jan Schwochow, Scrollytelling GmbH
- 01Video: getty imageshttps://www.gettyimages.com
- 02spectaris.dehttps://www.spectaris.de/
- 03trumpf-laser.comhttps://trumpf-laser.com