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.File | Dimensione | Formato | |
---|---|---|---|
Long-term benchmarking of laser technologies and process improvement for Cu hairpin welding in electric drive manufacturing.pdf
accesso aperto
:
Publisher’s version
Dimensione
1.17 MB
Formato
Adobe PDF
|
1.17 MB | Adobe PDF | Visualizza/Apri |
I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.