Industrial Laser Solutions for Electric Motor Manufacturing
Laser technology is quickly becoming a standard in the EV industry, as electric motor manufacturers need to scale up production, lower their environmental impact, and consistently produce high-quality parts.
Parts like stators, hairpins, rotors, and a range of castings are already manufactured using lasers. Whether it’s for laser marking or laser cleaning, Laserax has developed a range of laser solutions specifically for electric motor manufacturers.
Laser Processes for Electric Motor Manufacturing
Laser Stripping of Insulating Layer on Copper Hairpins
Copper hairpins are insulated with a coating that needs to be removed before they are welded to one another. Laser stripping can remove all types of insulating coatings, including polyamide-imides (PAI), polyether ether ketone (PEEK), and polyamide-imides with polyimide foil (PAI+FEP).
The laser removes the coating on the end of the hairpins, which is the area where the welding will be performed. This ensures that the coating does not contaminate the welds.
Unlike mechanical stripping, laser stripping removes the insulating layer without damaging the copper underneath.
Laser Cleaning of Epoxy Powder Coating on Copper Hairpins
After the impregnation process of the stator, copper hairpins are powder coated with epoxy resin. This coating needs to be removed from the end of some hairpins, as they will be connected to other parts during the e-motor’s assembly.
Laser cleaning removes the epoxy from these hairpins so that they are clear of contaminants before welding, providing an optimal current transfer to the stator.
Slip Ring Laser Oxide Removal
Laser oxide removal can remove oxides from slip rings. It ensures that no contaminants remain on the surface.
Since most slip rings are made of copper, laser cleaning is typically used to remove copper oxides, but other types of oxides can be removed as well if a different type of metal is used.
As a result of laser oxide removal, current transfer is optimal between slip rings and brushes. This increases the performance and lifespan of the Electrically Excited Synchronous Motor (EESM).
High Temperature Rotor Laser Marking
Laser marking can be used to mark rotor laminations and squirrel cages while their surface temperature is extremely high, such as after the casting process or a heat treatment. At high temperatures, the laser marking of metals like steel and aluminum is faster than usual, as lower energy levels are needed to etch the preheated surface.
Laserax offers different options to keep the laser equipment cool. Our options also include protection from contaminants like dust, water vapor, and oil particles in the air so that the laser maintains optimal performance with minimal maintenance.
The main advantage of marking rotors when they’re hot is to implement traceability early in rotor manufacturing. This provides as much production data as possible to optimize processes, lower scrap rates, and better respond to recalls.
High-Speed Laser Marking of Castings
When laser marking is integrated directly in the production line, the laser process and automatization features need to be fast to prevent bottlenecks.
Laserax offers the fastest solutions in the industry, with laser markers that outperform competitors’ lasers.
Our complete solutions include fume management, lens protection, class-1 laser safety, post-process resistance, barcode validation, and more. Built with industrial grade components, our lasers operate with low maintenance in harsh conditions.
Shotblast Resistant Marking of Castings
To implement traceability early in the casting process, parts need to be marked as soon as they’re out of the mold. But castings often undergo shotblasting, which affects the readability of codes and alphanumerical characters.
Laserax has developed a unique laser process to mark 2D codes that remain readable after shotblasting. This way, casters can implement traceability early and obtain the production data needed to optimize processes and minimize the size of recalls.
Typical castings that benefit from this process include motor housings, gearbox housings, inverter housings, bearing plates, rotors, and pump housings.
Benefits of Laser Technology for Electric Motor Manufacturing
With their many configurations, lasers can be adapted to meet all types of production line requirements. Offering high speed and easy automation, they are ideal to scale up electric motor production and simplify the manufacturing process.
Lasers can treat electric motor parts with the precision and consistency they need. With peripheral devices like sensors, they can be adjusted on the fly to account for positioning variations. Lasers make it easier to produce high-quality parts.
Low Ecological Footprint
With the electrification of the automotive industry, sustainable manufacturing processes are more important than ever. Fiber lasers can help manufacturers meet green goals by replacing polluting technologies. They are energy efficient, operate without consumables or chemicals, and have a long operating life.
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