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TRUMPF Lösungen im Bereich eMobility
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1. Automobile body - lightweight design

TRUMPF lasers are predestined for lightweight constructions and flexible production processes in the automotive industry. This is true in particular for the building of modern motor vehicles in the area of eMobility. Thanks to precise and pin-point manufacture it is possible to save considerably in weight and material when manufacturing automobile bodies.

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2. Powertrain

The electrified power train must withstand high mechanical loads. TRUMPF lasers enable the high-strength and durable joint connections required for this purpose.

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3. Battery system

Energy storage is the core element of any electric vehicle. The laser is ideal for its sensitive components, as it works reliably and without contact.

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4. Power electronics

Switches, plugs, sensor and actuators - TRUMPF customers use lasers to weld smallest electronic parts, as well as contacts and components for transferring high currents.

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Automobile body - lightweight design

Irrespective of whether the issue is component costs or weight - lightweight constructions with high number of variants and small quantities are a central objective in building electrical cars. TRUMPF lasers open completely possibilities for processing lightweight material: From aluminum to high-strength steel and fiber-reinforced materials - our lasers bring everything into precise and pinpointed shape. In the process the material is used optimally and is very versatile in terms of geometry. Your advantage: All this is possible without special tools.

Lasergeschweißte Tür für höchste Sicherheit bei geringem Gewicht
Door and window frames

TRUMPF lasers weld door and window frames effectively, using less material and in an attractive design. Reinforcement plates are also optimally integrated using this technology. For this we offer our customers solutions that considerably reduce the number of process steps and process chains. TRUMPF lasers set welding spots and welding seams in every shape and direction. Narrower flanges on the doors save material, weight and costs.

Verbinden von hypriden Verbindungen
B-pillars

To design lighter but at the same time safer car bodies hot stamping is increasingly used to produce structural parts. 3D-laser cutting cells give the final contour to these ultra high strength components. As flexible tool the laser also serves to create local soft zones in press hardened parts. This allows post joining or forming operations.

TRUMPF Laser in der Fertigung von E-Autos
Entire vehicle

Lightweight construction in the automotive industry is based on many new materials, compounds and the use of aluminum. For all these materials and their processing, TRUMPF has ideal beam sources and the corresponding process know-how. Furthermore, our application engineers at the TRUMPF Laser Application Center always find the correct parameters for your specific application.

Tackling E-mobility together

You want to know how we can optimally support your production on the path toward electrical mobility? Profit from the automotive know-how of our industry experts.

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Our product highlights for the automobile body construction


Powertrain

Compared to the petrol car, battery-electric drives have the advantage that the torque is available almost instantaneously. This, however, leads to the drives having to withstand higher dynamic requirements. For this reason a large number of high-strength connections therefore have to be made during production. TRUMPF lasers provide the requisite precision and productivity for this and enable the more compact design of the E-drives.

Leichtere Herstellung von Elektromotoren mit TRUMPF Lasertechnik
Electric motor

Hairpins are rectangular copper wires that are used in the grooves of the electrical plates of E-Drives and then welded at the front side. They replace round copper wires that were previously wound. TRUMPF lasers remove the insulating layer of paint in preparation for welding. The TRUMPF image processing VisionLine hereby ensures durably precise welds which are always located correctly. This provides you with highest quality combined with fastest throughput times and no reject parts.

Mit Laser gefertigtes Leichtbaudifferential
Lightweight differentials

Differentials in e-cars need to be increasingly lighter and at the same time more stable. The required material combinations made of cast-iron and case-hardened steel are difficult to join with conventional welding processes. However, the laser is the perfect tool for this purpose. Combined with extensive sensors it ensures welding seams in best quality. TRUMPF seam position control SeamLine Pro, for example, monitors the seams before, during and after the welding. The high-precision welds also contribute to a significant reduction in running noises of the differential gear.

Reinigen, schweißen und gravieren von hochfesten Materialien im Getriebe
Gearwheels

Gearwheels, driveshafts and intermediate shafts of high-strength materials are installed to increase the wear resistance of the gears. After the welding has been completed TRUMPF marking lasers engrave the components with designations of origin and data for optimum traceability. The recess in the base material is extremely resistant due to the material coating and guarantees permanent readability.

Tackling E-mobility together

You want to know how we can optimally support your production on the path toward electrical mobility? Profit from the automotive know-how of our industry experts.

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Our product highlights for powertrain


Battery system

Compact, securely installed and reliable in operation - these are the features required from the battery system of an e-car. However, the price increases at the same time as the power density. The efficient manufacture of laser machines with high productivity and lower part costs allows larger quantities to be produced more cost effectively.

Herstellung von Batteriepacketen mit lasergeschweißten Zellverbindern
Battery pack

The battery pack combines all battery modules and is welded to a compact block. Customers use TRUMPF lasers to weld the components and casing of the pack tightly and with high precision. The precision tool provides new solutions for the manufacture and integration of the cooling system. The quality of the welds is constantly monitored by intelligent sensors.

Herstellung von Batteriezellen mit TRUMPF Lasern
Battery cell

High quality cell connectors are decisive for the performance of the entire battery. TRUMPF lasers weld cell connectors of copper and aluminum as well as charged batteries safely, flexibly and with no contact. In the case of heat-sensitive workpieces, in particular, it is important to make high-strength welds with as little energy input as possible. With its innovative technologies such as oscillation welding (wobbling) or BrightLine Weld, TRUMPF opens the design capabilities for this.

Tackling E-mobility together

You want to know how we can optimally support your production on the path toward electrical mobility? Profit from the automotive know-how of our industry experts.

Request consultation

Our product highlights for battery systems


Power electronics

With e-vehicles in particular, the loss free power converting of the electrical plays a key part. Clean and high quality processed electronic components are required for the exchange of these enormous quantities of data. Laser-welded material-formed joints for loss-free current transport from the battery via the inverter to the engine.

Spritzwassergeschützte, saubere und dauerhafte Schweißverbindungen in Elektrofahrzeugen dank TRUMPF Laser
Power electronics

In electric vehicles the plugs, connectors and contacts must be splash-water protected, clean and permanently connected. To achieve this TRUMPF provides solutions in the area of copper welding with green laser light that causes almost no spatter. The wobbling technique or new technologies, such as BrightLine Weld for IR Lasers are suited for low-resistance connections between the battery and the power electronics. The laser welding also enables durably sealed plastic and aluminum housings. Customers also use TruMark marking lasers for durable and fast identification for traceability.

Lasergeschweißte Sensorgehäuse
Laser welded sensor housing

In the manufacture of housings for sensors in electric vehicles, our customers use the numerous advantages of the laser for spot and seam welding. For example, the generation of precise welding spots. In addition the targeted energy input of the laser for least possible disturbance of the sensitive electronics inside the housing.

Tackling E-mobility together

You want to know how we can optimally support your production on the path toward electrical mobility? Profit from the automotive know-how of our industry experts.

Request consultation

Our product highlights for power electronics

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