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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 manufacture B-pillars that offer maximum safety and are at the same time considerably lighter than an exclusively steel construction, automobile manufacturers rely on a combination of steel, high-strength steels and plastics. For such hybrid connections, TRUMPF offers secure, local joining processes. With the laser it is no longer necessary to use any filler material for welding.

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

Programmierbare Fokussieroptik PFO 3D
I-PFO

Enter the world of high-productivity remote processing "on the fly": The intelligent focusing optics I-PFO knows its own position in the robot's work area and the position and orientation of the processing points, e.g. welding seams, on the workpiece.

TruDisk, Höchstleistung aus der Scheibe
TruDisk

TruDisk, the interconnectable and intelligent high-power solid-state laser, is predestined for a large number of applications in the E-mobility branch, like, for example, the deep welding of wear-resistant gear wheels.

TruLaser Cell 8030, Das Bewährte noch besser
TruLaser Cell 8030

The compact TruLaser Cell 8030 cuts 3D components such as B pillars with high reliability and productivity and can be programmed very easily.


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

Programmierbare Fokussieroptik PFO 33
PFO 33-2

The focusing optics PFO 33-2 quickly positions the laser beam going from weld to weld. It can be programmed flexibly and, thanks to its image processing, even compensates component tolerances.

TruLaser Cell 3000, Einzigartig universell
TruLaser Cell 3000

You can cut filigree stator sheets, for example, with great precision on the TruLaser Cell 3000, thanks to its intelligent control and image sensor system.

TruDisk, Höchstleistung aus der Scheibe
TruDisk

TruDisk, the interconnectable and intelligent high-power solid-state laser, is predestined for a large number of applications in the E-mobility branch.


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

Programmierbare Fokussieroptik PFO 33
PFO 33-2

The focusing optics PFO 33-2 quickly positions the laser beam going from weld to weld. It can be programmed flexibly and, thanks to its image processing, even compensates component tolerances.

TruDisk, Höchstleistung aus der Scheibe
TruDisk

TruDisk, the interconnectable and intelligent high-power solid-state laser, is predestined for a large number of applications in the E-mobility branch.

TRUMPF Bildverarbeitung, Vertrauen Sie Ihrem Prozess
VisionLine

VisionLine, the intuitively operable image processing system, automatically detects geometric features on the component and reliably compensates for component tolerances.


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

Programmierbare Fokussieroptik PFO 33
PFO 33-2

The focusing optics PFO 33-2 quickly positions the laser beam going from weld to weld. It can be programmed flexibly and, thanks to its image processing, even compensates component tolerances.

TruDisk Pulse, Effizient Kupferschweißen
TruDisk Pulse

With the TruDisk Pulse 421, you will be able to weld copper more efficiently, with less spatter and higher welding seam reproducibility - all of this independent of the material surface quality.

TRUMPF Bildverarbeitung, Vertrauen Sie Ihrem Prozess
VisionLine

VisionLine, the intuitively operable image processing system, automatically detects geometric features on the component and reliably compensates for component tolerances.

Even more about TRUMPF in electromobility

E-mobility made with TRUMPF Laser
eMobility @ TRUMPF

Get an overview of how TRUMPF enables many new manufacturing possibilities in electric mobility.

Ihr Kontakt zu unseren eMobility Experten
Your contact to the experts

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 specialists in the area of bodywork, powertrain, lightweight construction, battery manufacture and power electronics.

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