Contacting and welding of the pin pairs is an important step in the manufacturing process. After the free ends of the pins are twisted together, they are contacted according to the specific winding scheme of the motor. This process typically involves 150 to 250 pin pairs that must be connected together.
To create a stable connection , the pin pairs are welded. The exact voltage situation varies from customer to customer, so flexible concepts are needed to meet the requirements. Careful contacting and welding ensures reliable connection of the pin pairs in the motor.
About 0.05 to 0.2 seconds are usually available for welding a single pin pair. A high energy input must occur in a short time, while nearby components must be protected from thermal damage. To meet these requirements, a powerful and flexible laser is used, which is especially suitable for hard-to-reach components such as the hairpin stator.
After welding, a thorough quality control of all welds is required. Various concepts exist for this purpose, including an innovative concept of our own, for which Gehring has applied for a property right. The control concerns aspects such as the bond cross-section, the permitted heat input, and the occurrence of pores and spatter.
Laser welding of copper materials requires special process know-how. Due to the low absorption of the laser and the high thermal conductivity of copper, the process window is very small. At the same time, high customer requirements for welding quality must be met.
The welding process represents one of the final stages in the value chain of hairpin stators. It is therefore crucial that the welds are robust and process-safe, otherwise the entire stator is defective and cannot be used or subsequently reworked. Therefore, process know-how plays a particularly important role.
The development of this know-how results from internal advances in technology development as well as from collaboration with external cooperation partners and universities. Furthermore, networking in the laser industry is of great importance in order not to miss the latest developments.
Internal technology and product development
And much more!
Contact us today and let our experts advise you. Together we will find the optimal solution for your individual requirements in flexible manufacturing. Increase your efficiency with Gehring!
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