TRUMPF Laser opens the automotive industry a multitude of manufacturing possibilities in all areas of electrical mobility. From high-end laser systems with the highest beam quality to intelligent quality assurance systems and the establishing of complete production plants, TRUMPF is a partner to its customers in the area of eMobility. With our deep knowledge of a variety of industries and applications and our worldwide laboratories, we support various industry sectors in understanding new technologies. Working together with them on many projects, we develop innovative solutions for the challenges of eMobility that arise. To do so we are 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.
More than 500 beam sources sold in worldwide battery production.
Around 50 million differentials are manufactured annually using laser technologies.
Up to 97% less spatter thanks to copper welding with green laser light.
Innovative E-mobility applications
Electric drives: Hairpin welding
To prepare hairpin welding, our customers use TRUMPF short-pulse lasers that remove the insulating paint coating without damaging the copper below. The process delivers more precise results than mechanical coating removal processes. Intelligent sensor systems ensure precise seams when welding the hairpin thus ensuring optimum quality. Thanks to the high reproducibility of the laser welding processes, our customers achieve consistently high-strength connections with good conductivity - and they do so in large quantities as well.
Welding of differential gears
TRUMPF lasers weld housings of differential gears with crown wheels, reliably, flexibly and without contact. They enable many multi material connections for light-weight construction. The combination of cast iron and case-hardened steel is the most common. The high-precision laser welding technologies also contribute to a significant reduction in undesired running noises of 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
With TRUMPF lasers, customers weld battery casings and cell connectors of copper and aluminum easily and with precise seams. Increasingly small and powerful cells are integrated in this manner in a battery array. An extensive system of sensors monitors the quality of the welding seams and guarantees precise welding penetration depth.
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.
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.
TRUMPF at the International Laser and Joining Symposium 2018
Marc Kirchhoff, Automotive Industry Manager at TRUMPF, gave his presentation on the current status of laser machining carbon fiber reinforced plastics (CFRP). You will also find more out about the most recent results on using lasers for hybrid plastic connections without additional joining materials.
Even more about TRUMPF in electromobility
Together with its customers, TRUMPF is developing customized manufacturing solutions for new challenges in the industry, in areas such as bodywork, powertrain, battery systems and the power electronics of electric vehicles.
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.