TRUMPF lasers open up a wide range of manufacturing options to the automotive industry in all areas of electro-mobility, paving the way for a mobile future. From high-end laser systems with the highest beam quality, to intelligent quality assurance systems, right up to the construction of complete production systems: in the field of e-mobility, TRUMPF is your reliable partner. With our extensive industry and application expertise, as well as our global laboratories, we help the sector to understand new technologies. In numerous projects and initiatives, together we develop solutions for the upcoming challenges posed by electro-mobility. Here, we get involved in the entire development process, from the initial idea to the start of production.
TRUMPF offers forward-looking solutions in laser-based production of electrical drives, especially in the process of assembling hairpin stators.
TRUMPF lasers enable the reliable, high-quality mass production of differentials for light-weight construction e-cars.
New processes and lasers in the green wavelength range allow precise and reproducible laser welding of copper with minimal spatter.
TRUMPF has developed industrial-suited technologies for laser welding and laser cutting of a wide variety of components in battery systems in electrical vehicles.
Innovative E-mobility applications
Electric drives: Hairpin welding
In order to prepare hairpin welding, our customers use TRUMPF short-pulse lasers that ablate the layer of insulating paint, without damaging the copper underneath it. Here, the results of the process are more precise than those of mechanical decoating processes. While welding the hairpins, an intelligent sensor system ensures precise seams and top quality. Due to the high level of reproducibility of laser welding processes, our customers achieve consistently high-tensile connections with a good level of conductivity – in a high quantity too.
Welding of differential gears
TRUMPF lasers weld the housings of differential gears with bevel gears reliably, flexibly, and without contact. Here, they enable the creation of numerous hybrid material connections for lightweight design. The most common of these is the combination of cast iron and case-hardened steel. The highly precise joining technologies using lasers also help to considerably reduce unwanted running noises from the differential gear during operation.
Spatter-free joining of copper and aluminum
Due to increasingly compact casings and the required higher conductivity of electronic components, the requirements for the joining technology of copper and aluminum components also increases. A newly developed, pulsed green laser from TRUMPF welds these materials with high reproducibility and eliminates almost all spatter - irrespective of the condition of the surface.
Connection of battery cans
TRUMPF lasers are ideal for sensitive battery cells and their casings, the cans, as they operate with no contact and with almost no energy input. The material is not subjected to mechanical load. The locally limited, low heat input caters for high-precision, distortion-free seams.
Welding of battery casings
Using TRUMPF lasers, customers can weld battery housings and cell connectors made from copper and aluminum effortlessly and with precise seams. In this manner, increasingly small and powerful cells can be integrated into a battery array. A comprehensive system of sensors monitors the quality of the weld seams and ensures precise welding depths here.
Cutting of stator plates
Manufacturers of electrical motors use TRUMPF lasers for cutting stator plates. Delicate contours can be cut very quickly and precisely. Our customers profit from high reproducibility and the lack of distortion, even when joining stator packages in prototype construction.
White paper: Laser welding of hairpins
Hairpins are essential in order to manufacture powerful electric motors for electromobility. In our white paper, you can find out more about how the laser assists you during production and processing. Register for our TRUMPF e-mail news now and download our white paper for free. You will receive deeper insights into the process and its applications in the field of e-mobility. You can unsubscribe from the TRUMPF e-mail news at any time.
White paper: New developments when it comes to laser welding of copper contacts, power electronics, and control units in the field of electromobility
Due to the continuous further development of the beam sources, the application results are also improved. For example, lasers with a green wavelength and sufficient power that are developed to industrial maturity mean that copper contacts can be processed more productively and practically without any spatter in the field of electromobility. You can read more about the latest developments and the numerous possible applications in electromobility in our white paper. Register for our TRUMPF e-mail news now and download our white paper for free. You can unsubscribe from the TRUMPF e-mail news at any time.
Always at the cutting edge of research
TRUMPF is actively involved in phase three of the Lightweight Forging Initiative. Around 40 international partners have been investigating for more than five years areas such as the lightweight potential of radically redesigned components in powertrains as well as chassis-and-suspension systems of hybrid cars. TRUMPF is also involved in many other development projects on new eMobility applications and on lightweight design for a forward-looking, resource-efficient electric mobility.