Automotive motors mainly include permanent magnet synchronous motors, asynchronous induction motors, and hairpin motors. Hairpin motors, with their high power density and superior heat dissipation, are widely used. Stators are categorized into traditional round-wire windings and hairpin windings, with the latter gaining popularity due to its higher slot fill factor and power density.

Laser welding technology offers significant advantages in stator manufacturing. Its high precision, efficiency, and minimal heat-affected zone make it particularly suitable for hairpin stator welding. By optimizing laser parameters, employing spot oscillation techniques, and integrating real-time monitoring systems, laser welding ensures high-quality and consistent weld seams while enhancing production efficiency. This technology has become an essential process in the manufacturing of new energy vehicle motors, facilitating the efficient production of high-performance motors.

Scope of Application and Technical Features

Automotive motors mainly include the following types: Permanent Magnet Synchronous Motors (PMSM), which are widely used in new energy vehicles for their high efficiency and power density; Asynchronous Induction Motors (ASM), known for their simple structure and low cost; and Hairpin Motors, favored for their high slot fill factor and excellent heat dissipation performance. Correspondingly, stators come in two main types: traditional round-wire wound stators and hairpin wound stators, with the latter becoming mainstream due to its higher power density and heat dissipation.

The technical processes and key points for laser welding of stators are as follows:

1. Laser Parameter Optimization: Adjust laser power, spot size, and welding speed according to material properties (e.g., the high reflectivity of copper) to ensure welding quality.
2. Spot Oscillation Technology: Use spot oscillation to cover the cross-section of hairpin wires, forming uniform welds and enhancing welding strength.
3. Welding Path Design: Select appropriate welding paths, such as linear, circular, or elliptical oscillation, based on the welding position.
4. Real-Time Monitoring and Feedback: Utilize image recognition and sensors to monitor the welding process in real-time to ensure weld seam quality.

Key considerations include:

1. Control of Heat-Affected Zones: Precisely control heat input during laser welding to avoid damaging the insulation layer of silicon steel laminations.
2. Material Compatibility: Ensure the laser welding process is compatible with different material properties, such as the high reflectivity of copper and the high silicon content of silicon steel laminations.
3. Equipment Stability: Laser welding equipment must be highly stable to meet the demands of continuous, long-term production.
4. Safety Protection: Equip the laser welding process with safety devices to protect operators from laser hazards.

The welding effect of laser welding on automotive motor stators

Producing automotive motor stators using automated laser welding production lines offers significant advantages in terms of welding quality, efficiency, and yield:

1. High Welding Quality
   Laser welding is characterized by its precision and high energy density, resulting in minimal heat-affected zones and reduced welding deformation. This ensures strong and aesthetically pleasing weld seams. Additionally, by precisely controlling welding parameters such as power, speed, and spot size, laser welding significantly enhances the quality of the welds.
2. High Welding Efficiency
   Laser welding is fast and significantly reduces production time compared to traditional methods. The integration of robots and advanced control systems in automated production lines enables the entire process—from loading to welding to unloading—to be fully automated, further improving production efficiency.
3. High Yield
   The precision and stability of laser welding equipment, combined with the accurate control of automated production lines, can achieve a welding yield as high as 99.99%. Moreover, real-time monitoring and feedback systems allow for immediate adjustments to welding parameters, ensuring the stability of the welding process.

In summary, automated laser welding production lines for automotive motor stators not only improve welding quality and efficiency but also significantly increase yield, bringing higher production efficiency and economic benefits to enterprises.