Busbar Laser Welding for Power Electronics

TRUMPF’s patented BrightLine Weld technology improves busbar welding by reducing weld spatter by up to 90%, minimizing heat input, and enhancing electrical conductivity and structural integrity. It ensures cleaner, faster, and more stable welds, boosting efficiency and quality in battery pack production.

Contaminated protective glass can cause laser power loss during busbar welding, leading to reduced penetration depth. With TRUMPF’s CalibrationLine function, both laser power and focus are automatically monitored and calibrated, ensuring consistent weld quality and reliable process performance.

The VisionLine OCT Check process sensor system enables reliable and precise monitoring of weld depth using optical coherence tomography (OCT). This allows for real-time, process-synchronous quality assurance, such as measuring keyhole depth during deep welding. Thanks to the seamless integration of the PFO and OCT, consistent keyhole depth measurement is possible across the entire PFO work area—without the need for parameter adjustments.

The system records process data and stores it in flexible storage locations. This data stays with you locally. This means that your data quality assurance is automated. For seamless traceability, you can assign the applicable relevant process data from the laser, the optics or other process sensors to each component. This enables you to analyze data over several processes as well, and it subsequently makes it easier to determine the cause of quality defect.

Power electronics are typically housed in environmentally sealed cast aluminum enclosures. Traditional sealing methods—such as gaskets and screws—add time, cost, and offer limited durability. TRUMPF’s multi-focus optic technology enables laser welding for hermetic sealing of cast aluminum housings, delivering faster, more cost-effective production and long-lasting protection against environmental influences.

A smart camera is integrated into TRUMPF’s welding optics through the AI-powered VisionLine system. It significantly improves position detection of even the smallest components before welding and evaluates weld quality based on the surface condition of the weld bead. Combined with in-process monitoring, it provides a comprehensive quality check—directly within the welding station.