Industrial Laser Solutions for Electric Motor Manufacturing

Gasketing/Bonding Surface Preparation

Laserax’s cleaning and texturing technology removes contaminants and modifies the part’s surface roughness if required for a stronger and more durable bonding process. Laser surface preparation also introduces a layer of oxides that is beneficial for bonding in addition to the surface roughness that promotes adhesion.

Epoxy Removal of Stator Connector Tabs

Once EV stator are coated with epoxy, laser cleaning can be used to remove the coating from the connector tabs to get clean copper surfaces prior to welding the connectors to other parts of the e-motor. Using laser for this task eliminates the need for manual masking operations.

This process is often performed with the laser head mounted on on an industrial robot arm. An extraction nozzle is installed on the robot arm to capture dust and fumes at the source. It is essential to prevent contaminating surfaces or damaging connections and electronic components.

Rotor Surface Preparation and Marking

The rotor‘s shaft can be cleaned with a laser before it is press fitted into the rotor’s core. This process removes oil, dust, or any contaminants remaining from its manufacturing.

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.

High Speed Marking of Critical Parts

When laser marking is integrated directly in the production line, the laser process and automation features need to be fast to prevent bottlenecks.

Laserax offers the fastest marking solutions in the industry. Our laser markers also outperform competitor’s lasers by their ability to mark parts while the surface temperature is extremely high.

Laserax has also developed a unique laser process to mark 2D codes that remain readable after processes such as shotblasting and e-coating.

Pinions Phosphate & E-coating Removal

E-coating needs to be removed from several areas of a driveshaft before assembly. Instead of masking the assembly areas prior to e-coating, a fiber laser is used to remove the coating from localized areas. The laser process is precise and consistent, and the resulting cleaning quality is perfect.

Laserax offers the fastest marking solutions in the industry. Our laser markers also outperform competitor’s lasers by their ability to mark parts while the surface temperature is extremely high.

Phosphate coating needs to be removed from pinions and ring gears to improve mechanical properties before the assembly. The process leaves the metal underneath unaffected and helps create a stronger assembly.

Slip Ring Oxide Removal

Laser 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).

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.

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.

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