WELDING
During the welding process - powered by Gehring - the coils formed by placement/connection of the pins and twisting the ends of the pins are closed so the electrical flow can be generated in accordance with the specified winding diagram. The quality of the welded joints has a direct influence on the subsequent performance of the stator and the electric motor.
For this reason, the pins must have the required connection area. Otherwise, when the stator is in operation high resistances may be encountered in the coil and this will reduce the efficiency. The welded joints must also withstand mechanical stresses, which, for example, may be caused by vibration generated during operation.
Our fully automatic welding plants reach the required quality and cycle time with the corresponding degree of automation using the same laser technology used in the automotive industry. In addition to the selection of suitable laser components, customized processes have been developed, tested and applied in mass production with specific laser configurations and parameter settings suited to specific components. The modular machine design enables a very wide range of customized cycle times. Different welding technologies can also be integrated into the existing modular machine platform to enable specialized welding processes.
AUTOMATIC PROCESS:
- Modular machine design with easy scalability
- Automatic clamping of the Hairpins for welding
- Welding multiple Hairpins in one clamping process
- Integrated protection from weld spatter
- Optimized welding configuration for traces of powder, pores and droplets
- Time-optimized loading and unloading system
- Virtually 100% usage of the beam source
The welded and closed coils are electrically insulated by the concluding impregnation.