Core Technology of Hairpin Motor Laser Stripping and Welding

In the context of the booming development of the new energy vehicle (NEV) industry, the motor, as the core power conversion component of NEVs, plays a critical role. Its performance optimization and cost control are directly related to the vehicle’s energy efficiency, driving range, and market competitiveness.In recent years, with the market’s continuous pursuit of high performance and low energy consumption in new energy vehicles (NEVs),hairpin motors, with their significant advantages of high efficiency, lightweight design, and low loss, have gradually become a standard feature in NEVs.

Hairpin Motor

Compared to traditional round-wire motors,hairpin motors mainly alter the arrangement of the copper wires in the stator winding, with winding forms such as Hair-pin and X-pin. After the copper wires are tightly arranged, they are welded on one side. This not only reduces the size of the motor but also increases the slot fill factor, significantly improving power density, reducing energy consumption, and driving the motor’s development towards miniaturization, lightweight design, and high performance. This innovation is leading the transformation of powertrains in new energy vehicles (NEVs). Currently, the penetration rate ofhairpin motors in the mid-to-high-end NEV market continues to rise. According to a forecast by the Future Think Tank, the penetration rate ofhairpin motors in NEV drive motors is expected to exceed 90% by 2025.

The next-generation laser solutions meet higher intelligent manufacturing demands.

As the industry progresses, the production ofhairpin motors demands higher precision and efficiency. In the manufacturing process ofhairpin motors, paint removal and welding, as critical front-end processes, are key to the production chain and serve as bottlenecks restricting capacity and quality improvement.

Against this backdrop, laser technology, with its non-contact processing, high precision, high efficiency, and environmentally friendly characteristics, has emerged as the ideal solution to address the manufacturing challenges ofhairpin motors.

 

Laser paint removal process: precise paint removal with no damage to the substrate.

Before welding, it is necessary to remove residual insulation layers, non-insulated areas, and adhesive layers from the surface of the copper wire. The process requires high-speed handling, clean and smooth edges, while ensuring that the insulation material is not thermally damaged and the surface remains free of oxidation.

Compared to traditional processing methods, laser paint removal enables high-precision control, avoiding damage to the copper wire itself, while significantly reducing the use of chemical consumables, aligning with the green and environmentally-friendly direction of manufacturing industry development.

Results of laser paint removal

HGTECH specializes in developing laser paint removal solutions for hairpin motors, creating a series of intelligent laser equipment, including CO2 and fiber lasers. The company employs the next-generation Pulse adjustable laser technology. Through innovative mechanical structure design and advanced algorithms, it precisely controls the laser beam’s focusing path. Achieves 360-degree precise processing, with one-pass paint removal, providing stable and controllable quality assurance for motor manufacturing, and offering industry clients a personalized, customized service experience.

Intelligent Equipment for Laser Welding of Hairpin Motors

Applied to stator welding in flat wire motor copper wire processing, using a high-power small core diameter central beam, combined with the corresponding ring light power for deep fusion welding, achieving low heat-affected zone, low spatter, no porosity, and stable, high-strength welding. Customizable small core diameter lasers can be used to achieve ultra-low heat input deep fusion welding, compatible with X-pin welding.

 

Quality: Utilizes advanced annular fiber laser, welding strength > 1400N, with no porosity, spatter, or enamel ablation; porosity rate < 10%.

Stability: Advanced dual-beam coupled hybrid welding technology enables stable ball fusion welding and deep fusion welding, with a defect rate ≤ 5%.

Efficiency: Full-field laser processing system, one-pass forming, achieving a 200% improvement in welding efficiency compared to the previous generation, and over 30% increase in overall line efficiency.

Convenience: Intelligent dynamic parameter library that real-time matches welding parameters, ensuring an intelligent and efficient production process.