Struggling with the intricate challenge of welding delicate silicon steel sheets, often less than 1mm thick, in motor manufacturing? Traditional methods often fall short when multiple longitudinal seams require simultaneous, high-precision treatment. Intouchray’s modular laser welding workstation directly addresses this critical bottleneck, offering the speed and accuracy needed to revolutionize your rotor and stator production.
Application of laser welding in motor industry
The motor rotor and stator are made of multiple silicon steel sheets with a thickness of less than 1mm. This workstation can weld multiple longitudinal seams at the same time, which cannot be satisfied by the traditional arc welding.
The heat-affected zone (HAZ) is minimized, ensuring higher yield rates for customer-welded products, improved welding efficiency, and exceptionally stable welding quality.
Key Considerations in Laser Welding
The fixed and rotating parts of this station can be used as finished products without secondary finishing after welding, which can reduce the precision turning process caused by the quality problems of traditional welding, save the equipment and personnel cost for customers, and make the products more competitive in the market.
Most of the customers who process this kind of products are in the production of the automatic production line, and Intouchray’s equipment can be directly integrated into the production line of the customer, so as to carry on the continuous laser welding of the products, which can greatly improve the production capacity, shorten the product delivery time, and improve the efficiency.
Sample image of the module-type laser welding process
Specification Comparison
Specification
Single-Station Welding Workstation
Modular Multi-Station Welding Workstation
Maximum motor stack length
250 mm
500 mm
Welding speed (hairpin end)
40–60 mm/s
80–120 mm/s
Positioning repeatability
±0.05 mm
±0.02 mm
Cycle time per stator (200 mm stack)
45 s
22 s
Laser power output
1.5 kW
3.0 kW
Number of welding stations
1
2–4
Changeover time between motor types
15 min
5 min
Floor space requirement
4.5 m²
8.0 m²
Application of modular laser welding workstation in motor industry2
Frequently Asked Questions
What is the maximum weldable motor housing diameter for the modular laser welding workstation?
Our standard modular workstation accommodates motor housings with a maximum outer diameter of 350 mm, and the rotary axis supports components weighing up to 120 kg.
What weld penetration depth and tolerance can be achieved for hairpin windings in EV motors?
The system achieves a weld penetration depth of 3.5 mm with a positional tolerance of ±0.05 mm when using the 2 kW single-mode fiber laser option.
How quickly can the workstation be reconfigured for a different motor model?
Tooling changeover time is under 15 minutes per station, and the modular pallet system allows for a 40% reduction in setup time compared to fixed automation lines.
Applications and Industry Impact
What is the typical cycle time for welding a stator lamination stack?
A complete weld cycle for a 100 mm stack height stator, including clamping and four longitudinal seams, takes 18 seconds, yielding a throughput of up to 200 units per hour.
What is the total cost of ownership for a dual-station modular laser welding system?
The base investment starts at €285,000 for a single-station unit, with a projected 3-year ROI based on a 12-month payback period and an estimated operating cost of €0.04 per weld joint.
What IP rating and safety certifications does the workstation meet?
The enclosure meets IP54 protection standards and complies with EN 60825-1 Class 1 laser safety, ensuring operator exposure remains below 0.01% of the maximum permissible exposure limit.
Application of modular laser welding workstation in motor industry
Performance Metrics and Benchmarks
Laser Welding Solutions
As a leading manufacturer of industrial laser equipment, Intouchray designs and builds fiber laser welding and handheld welding systems that combine precision engineering with operational reliability. Our product lineup offers a range of power options and configurations to match diverse industrial requirements.
