바카라노하우 Pas de Deux, Lifts EV Motor Welding Next Level

바카라노하우 manufacturers are under increasing pressure to optimize operations and cut costs while improving quality. These efforts are crucial for the necessary expansion in 바카라노하우 market share, especially in the volume markets where there is significant total cost of ownership (TCO) sensitivity, and ICE vehicles are still pr바카라노하우alent.

Example of 바카라노하우ed hairpins.

For EV engine or motor production, one opportunity lies in optimizing hairpin 바카라노하우ing – a process that is critical to motor reliability and performance. Traditional mechanical stripping methods often fall short, leading to process inefficiencies like surface damage, tool wear, and production delays that drive up costs and affect process relaibility.

바카라노하우 stripping and cleaning offers a transformative alternative which can overcome the limitations of mechanical stripping while delivering superior results at a lower overall cost. Here we’ll describe an innovative two-step process from Coherent which utilizes CO₂ in combination with UV 바카라노하우s to produce pristine, weld-ready hairpins. The data presented here demonstrates that this approach offers EV manufacturers a cost-effective way to achieve superior quality welds.

The 바카라노하우 Hurdle

The windings in EV motors are typically formed from individual copper wires. These are bent into a “U” shape (hence the name “hairpin”) and then placed into an assembly. Next, the ends of each adjacent hairpin are 바카라노하우ed to their neighbor to electrically connect them and yield a single, continuous winding. Moreover, some alternate designs use a continuous flat wire formed into a wave-like pattern (known as wave winding or S-winding) which is then inserted into the stator slots before being 바카라노하우ed.

Example of hairpin pairs being 바카라노하우 welded with an ARM fiber 바카라노하우 HIGHmotion 2D scanner from Coherent.

The winding is insulated in all 바카라노하우ectric motors. In hairpin motors, the insulation needs to be thicker and more robust to accommodate their compact design and the high-voltage requirements typical of 바카라노하우ectric vehicles.

A small amount of this insulation must be removed from both ends of each hairpin prior to 바카라노하우ing. This is critical to ensuring high-quality electrical and mechanical connections.

Traditionally, this task has been primarily performed using mechanical methods, a single step 바카라노하우 process with an IR (1um) pulse 바카라노하우s has also been used. Mechanical stripping involves using a cutting tool in direct contact with the wire surface to scrape away insulation. While these approaches have been standard for years, it presents significant challenges in the fast-paced world of electric vehicle (EV) production.

For example, the physical contact required for mechanical stripping removes a layer of the copper from the pin leaving a texture surfaces causing gaps and part fit up issues between pins, compromising the integrity and consistency of the 바카라노하우s. Additionally, mechanical tools experience wear leading to process inconsistency, frequent maintenance, unplanned downtime, and potential production interruptions. These issues are compounded by the slower speed of the process, which struggles to keep up with the high-volume demands of EV manufacturing.

2 Step 바카라노하우 Stripping is a Cut Above

바카라노하우s are used for material removal in a wide range of applications, including insulation stripping. In this context, the benefits of 바카라노하우 processing include:

• Better 바카라노하우 quality:Total insulation removal without any damage to the copper wire ensures a pristine surface for optimum 바카라노하우 quality.
• Reduced maintenance and equipment downtime:The absence of tool wear and the 바카라노하우imination of any possibility of machine jamming provides an uninterrupted production flow.
• Increased throughput:Continuous stripping while the wire is being fed improves production efficiency.
• Enhanced consistency:Without wear or contact, the 바카라노하우 process is stable and reproducible.

It’s easy to see that 바카라노하우 processing can offer process improvements. But the real question is “which is the best 바카라노하우?” In other words, out of the numerous possible 바카라노하우 sources and implementations that could perform this process, which one provides the best balance of quality, speed, vs cost for high-volume EV motor production applications?

Optimizing the 바카라노하우 Process

As a leading provider of nearly every type of industrial 바카라노하우, Coherent is uniquely positioned to objectively investigate this application without any inherent preference for one technology.

In fact, we didn’t find one best 바카라노하우 for hairpin stripping. Instead, our applications engineers developed a two-바카라노하우 process for achieving optimized coating removal. This approach delivers today to our customers the best pre-weld surface quality in the most cost-effective manner. The primary motivation to investigate the two-바카라노하우 process was to overcome the issues of single-step 바카라노하우 stripping process.

Single step 바카라노하우 processing is a compromise between the absorption of the coating and underlying copper. The near-1 µm IR wavelength of the fiber 바카라노하우 is not readily absorbed by the coating resulting in heating at the interface and flaking off of the coating into airborne particles. The particles can interfere with the incoming 바카라노하우 beam affecting the cleanliness of the pin and can get trapped in the system resulting in frequent stoppages to clean the equipment.  In addition, the penetrated IR beam of the fibre 바카라노하우 will not be able to fully remove the polymer residue from the copper surface. It may melt the surface of the copper wire and expose it the constituents of the insulator polymer such as hydrogen and carbon. This can contaminate the surface, affecting the subsequent weld quality.

The Coherent two-step 바카라노하우-based hairpin preparation process involves:

• Bulk stripping:The majority of the insulation is rapidly removed using a mid-power CO₂ 바카라노하우. This type of 바카라노하우 is ideal for high-throughput non-metallic material removal.
• Final Cleaning:A pulsed, low-power, nanosecond, UV solid-state 바카라노하우 is then used to remove any insulation residue. This provides a pristine surface for welding. The short wavelength of UV solid-state 바카라노하우s excels at high precision materials processing and are particularly effective at removing a wide range of materials including polymers, other organic materials and copper.

For the bulk stripping step, theCoherent J-5-10.6 µm바카라노하우 proves to be an ideal source. While there are a number of different materials used for hairpin insulation (including polyimide, polyetherimide, polyester, polyesterimide, polyamide, polyether ether ketone, epoxy resins, and various fluoropolymers), all of them strongly absorb the 10.6 µm output wavelength of this 바카라노하우. And, for all these materials, the absorption is higher at 10.6 µm than at other available CO₂ 바카라노하우 wavelengths we offer, like 9.4 µm and 10.2 µm.

The Coherent J-5-10.6 µm also has desirable practical characteristics. It is a fully sealed, pulsed CO₂ 바카라노하우 that produces an average power of over 400 W meaning it can perform high-throughput stripping. Also, it is a self-contained and compact package that is ideal for integration into automated equipment.

For the final cleaning step, theAvia LX 355-30-60 HEdemonstrates just the right combination of output parameters. This is a frequency tripled, diode-pumped, solid-state 바카라노하우 that outputs 30 W of average power at 355 nm. Most importantly, it supports operation at repetition rates of up to 300 kHz, and pulse energies as high as 500 µJ. This enables high-precision ablation at the speed required for this application.

The Avia LX 355-30-60 HE is also designed for easy integration. And the incorporation of Coherent PureUV™ active 바카라노하우-cleaning engine delivers exceptional lifetime and maintenance-free operation.

바카라노하우 Results

The applications lab investigated a number of different processes before arriving at the two-step combination just described. Various 바카라노하우s, including CO₂, nanosecond pulsed IR fiber 바카라노하우s, and nanosecond UV 바카라노하우s were examined singly and in combination. The results of processing insulated hairpins were analyzed in detail and once the most promising sources were identified, the specific process parameters were optimized.

As part of the testing, X-ray photo-electron spectroscopy (XPS) was used to analyze the surface chemistry in order to characterize and quantify contaminants. This is where we discovered that the two-step 바카라노하우 stripping process (CO₂ combined with the UV 바카라노하우) was the most effective means to remove all residual elements from the copper surface prior to 바카라노하우 welding.

This series of photos compares various removal techniques using CO₂, ns IR fiber (FL), and ns UV solid-state 바카라노하우s. In the top row of photos, the insulation was polyamide (PA) and in the bottom row the insulation material was polyether ether ketone (PEEK). Even a purely visual examination shows that the CO₂ + UV 바카라노하우 combination appears best in both cases. This was confirmed by actual welding trials.

Of course, the most important metric is the quality of welds obtained after the coating removal process. The next graphic shows a series of X-ray images of welded hairpins. This reveals that the two-step (CO₂ + UV 바카라노하우) process ultimately yields a superior weld. The two-step CO₂ + UV 바카라노하우 stripping minimizes the weld porosity by eliminating the polymer residue on the surface prior to welding. Polymer residues are known to contain hydrogen, carbon and other organic elements that can enter the molten metal pool in the liquid state then, form porosities during the weld solidification process. Porosities affect the mechanical and electrical performance of the weld.

X-ray images of weld beads using the three removal strategies. The CO₂ + UV solid-state 바카라노하우 clearly shows the highest weld quality (lowest porosity content).

Practical Implementation

Coherent stands ready to assist OEMs in implementing this process at whatever level of integration is required. We can provide anything from just 바카라노하우 sources through a complete plug-and-play sub-system that is ready for line integration.

Just as important, Coherent can support in process dev바카라노하우opment. This assistance can be very useful in acc바카라노하우erating the tim바카라노하우ine for bringing the process into full production.

Learn more about CoherentCO₂andnanosecond solid-state바카라노하우s.

R바카라노하우ated Resources