As the use of electric motors in automobile power trains increases, it is crucial to develop a robust and stable stator welding process. The stator is the stationary part of an electric motor – an electromagnet made up of a core and an electrically conductive wire. For automotive power train manufacturers, it is vital to devise a stator welding process and equipment that guarantee 100% process quality in a full automotive power train production line.
Stator welding application engineers typically begin by focusing on the mechanics of making a single good connection. However, these mechanics change depending on the type of wire used and the type of weld equipment, among other differences. One kind of wire that has to be approached in a unique way is the “hairclip” wire, a nickname for the thick insulated wire bent into a C shape. Laser welding is one of the most frequently used technologies for hairclip welding of thick wires in industries with high production volumes.
Another method that can be used for automotive powertrain stator wire welding is hot crimping. The hot crimping process has seen a recent surge in use due to increased electrification in vehicle design. Hot crimping allows joining of wires to one another, or to terminals. Hot crimping creates an excellent mechanical and electrical connection, particularly when more than one wire is being joined together, due to the compression of the heat-collapsed metal on the wires. The hot crimping process is far more efficient in terms of cost, time, and effort than other wire stripping and joining processes—it combines the separate steps of stripping and joining into one automated process.
Check out the second part of this blog to read about more types of automotive power train stator welding.