Remote laser welding is typically exploited for the joining of hairpin couples for the manufacturing of electric drives. Laser welding of copper hairpins poses several challenges due to the high optical reflectivity and elevated thermal conductivity of the material. Moreover, the welding operation is required to be clean, since it is carried out in a sub-Assembly of the electric drive. The contemporary laser systems provide numerous possibilities for the welding process in terms of beam shapes and wavelengths. Hence, comparative analyses with well-defined criteria and protocols are required to assess the available technologies. Accordingly, this work illustrates the benchmarking of different laser welding systems in terms the mechanical strength and the process cleanliness during the welding Cu hairpins. Moreover, the monitoring approaches are described to ensure quality in a broad and distributed production environment. Additionally, mid-fidelity simulation is proposed to address the rapid selection between different beam solutions. The results of the presented framework presented are used to infer future beam configurations.

Long-Term benchmarking of laser technologies and process improvement for Cu hairpin welding in electric drive manufacturing

Demir A. G.;D'Arcangelo S.;Caprio L.;Borzoni G.;Previtali B.
2024-01-01

Abstract

Remote laser welding is typically exploited for the joining of hairpin couples for the manufacturing of electric drives. Laser welding of copper hairpins poses several challenges due to the high optical reflectivity and elevated thermal conductivity of the material. Moreover, the welding operation is required to be clean, since it is carried out in a sub-Assembly of the electric drive. The contemporary laser systems provide numerous possibilities for the welding process in terms of beam shapes and wavelengths. Hence, comparative analyses with well-defined criteria and protocols are required to assess the available technologies. Accordingly, this work illustrates the benchmarking of different laser welding systems in terms the mechanical strength and the process cleanliness during the welding Cu hairpins. Moreover, the monitoring approaches are described to ensure quality in a broad and distributed production environment. Additionally, mid-fidelity simulation is proposed to address the rapid selection between different beam solutions. The results of the presented framework presented are used to infer future beam configurations.
2024
Proceedings of the 13th CIRP Conference on Photonic Technologies [LANE 2024]
Beam shaping
Blue laser
E-mobility
Green laser
Laser welding
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Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/11311/1276197
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