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TRUMPF powertrain application stator

Laser welding drive components for electromobility

One of the core drive components is the electric motor. Our highly integrated and scalable copper welding processes are already industry standard and play a decisive role in the quality of the contacting, thereby achieving the maximum possible range for the vehicle. Electrified drives have the advantage that the torque is available almost immediately. However, this does mean that the drive components must be able to withstand higher dynamic demands. For this reason, laser processes for high-tensile materials are an absolute must during production. TRUMPF advises its customers on planned applications of all drive components and checks concrete application cases. Our lasers offer the precision and productivity required – even for high quantities. No matter which assembly it is – a differential, hairpin, busbar, rotor shaft, gear wheel, stator or its housing – laser processing makes the more compact design of electric drives possible in the first place.

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Applications in the powertrain sector

Processing high-tensile steels

Compared to conventional drives, electrified powertrains are heavily exposed to other operating conditions. For example, due to the high torques of the e-drives, direct stress is placed on the components, putting them under strain. Lasers make it possible to weld high-tensile steels with tear-resistant seams. Modulated laser welding opens up totally new areas of application, realizing further lightweight construction potential.

Welding copper hairpins

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. The procedure provides more precise and faster results than mechanical stripping processes, and intelligent sensor systems ensure precise seams and top quality when welding hairpins. Thanks to the high level of reproducibility of laser welding processes, our customers achieve consistently high-tensile connections with a good level of conductivity – and this in high quantities as well.

Joining differential gears

TRUMPF lasers weld housings of differential gears with bevel gears safely, flexibly and without contact. They facilitate the creation of hybrid material connections for lightweight construction. 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.

Laser hardening

TRUMPF lasers can partially harden heavily stressed components. Compared to conventional hardening processes (in ovens, for example), hardening with a laser is characterized by a very high level of energy efficiency. As the energy input by the laser is locally restricted, there is less distortion of the complete component overall. This reduces the number of rejects; production is optimized.

Coating brake disks with EHLA

TRUMPF is accelerating tried-and-tested laser metal deposition considerably with the new EHLA process ("extremely high-speed laser metal deposition"). This makes it possible to coat larger components such as brake disks at over 250 square centimeters per minute. This coating reduces the fine particulate abrasion and wear to the brake disk. This increases downtimes, and the brake disk is protected from corrosion at the same time. This is particularly important as electric cars brake less, making the brake disks especially susceptible to rust.

Complete TRUMPF solutions for the powertrain

Image processing for cutting and welding applications
VisionLine for characteristics recognition

You avoid defective parts with VisionLine. The image processing detects preprogrammed structures on the component and can therefore optimize the welding process in an automated manner. This increases the throughput time and reduces rejects at the same time.

TruLaser Cell 3000, unique and universal
TruLaser Cell 3000 with VisionLine and welding depth sensor system

Benefit from our complete package for optimized welding of components with continuous quality check. Sampling is obsolete as rejects are detected immediately. At the same time, you are taking advantage of optimum process monitoring as well as continuous documentation and traceability.

TRUMPF OCT image processing
OCT characteristics recognition

In addition to VisionLine image processing, three-dimensional contour measurement is also possible. This means you can follow the height difference accurately as well. At the same time, the welds of the hairpin pairs can be measured exactly during hairpin welding.

TRUMPF laser application hairpin welding with visionline
BrightLine Weld for hairpin welding

Our BrightLine Weld technology scores highly not only due to a higher feed rate, but it also makes it possible to weld copper with reduced pores and spatter. This means you benefit from less reworking on the component with less contamination in the machine itself at the same time. You also reduce maintenance times, while actively increasing the active operating time.

EasyModel AI for laser welding

Expand the VisionLine Detect options with EasyModel AI. The cloud-based AI training platform makes it possible to achieve good results without programming knowledge and with little training data. This allows you to train image-based AI models precisely to your requirements and your component.

Laser marking with TRUMPF products
Seamless and continuous documentation

The TRUMPF Quality Data Storage records process data and stores it in flexible storage locations to automate your data quality assurance. For seamless traceability, you can assign the applicable relevant process data from the laser, the optics or other process sensors to each component.

E-mobility consulting

Would you like to know how we can provide you with optimum support on your path to electromobility? Benefit from the automotive expertise of our industry experts.

An overview of the advantages of TRUMPF

Tailor-made product portfolio for specific applications in the powertrain range

Regardless of whether electrical steels or aluminum die casting are to be welded, our TruDisk lasers can be used very flexibly in almost every powertrain application thanks to their high beam quality and unique disc laser characteristics. They provide reproducible process results and high throughput times. The TruMicro short-pulse and ultrashort pulse lasers from TRUMPF are also used for laser-cleaning of sealing surfaces in stator housings. Regardless of the actual beam source and the specific application – you will always get everything from one source at TRUMPF – advice, application development, all laser equipment and service.

Laser-optimized construction and planning

TRUMPF can draw on a great wealth of experience of countless gearbox and e-drive applications and projects. We can therefore offer extensive consultation services in laser-compatible construction and optimization, even in the design phase and for existing products. We help you to select the right material and develop perfect processes, including all specifications unique to the production such as distortion, cycle times or tolerances.

TRUMPF – committed to innovation

We see ourselves as your application consultant and enabler for new production opportunities. Benefit from our consolidated industrial expertise and our decades of experience as a laser pioneer.

Established globally, active locally

Take advantage of a consultation with our experts and our worldwide laboratory and service network. Whether you need service or application development – we are where you are.

The TRUMPF Laser Applications Center in Ditzingen

TRUMPF Laser Application Center Ditzingen

Many cases, one worthwhile visit

Spanning an area of over 4,000 m², the TRUMPF Laser Applications Center in Ditzingen is one of the largest laser application centers in the world. Using your actual component, our application specialists and industry experts will support you during application development and optimization in the Laser Applications Center – with our extensive portfolio of versatile laser processing systems.

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TRUMPF laser welding option BrightLine Weld
Spatter-free laser welding with BrightLine Weld beam formation technology

You can weld materials such as mild or stainless steel or even copper and aluminum with almost no spatter thanks to the patented TRUMPF BrightLine Weld technology.

Welding copper

High-strength connections which are also entirely reproducible and have high conductivity can be achieved with non-contact tools.

Sensor system

As a complete system provider, TRUMPF also supplies process sensor systems. The continuous process monitoring increases quality and enables you to control your process accurately and reliably.

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