This equipment serves as a critical terminal station within a flat-wire stator production line; its function is to weld the hairpin ends—following the twisting process—into robust electrical connection terminals.
The equipment offers a choice between two welding processes: TIG welding or laser welding. The TIG welding option features a single-point cycle time of 2 seconds and achieves a pull-out force of ≥500 N.
The laser welding option utilizes a 6 kW power source (configured as 4+2 or 2+4 channels) and possesses deep-penetration welding capabilities, making it particularly well-suited for welding mini-pin terminals (≤4 mm); it achieves a pull-out force of ≥300 N.
The system integrates a comprehensive suite of functions, including rapid positioning via SCARA robots, a water-cooling unit, a dust extraction and purification system, MES data monitoring, and one-touch recipe switching for model changeovers.
Suitable for welding the copper end faces of flat-wire stators for new energy vehicle drive motors, specifically following the wire-twisting process.
TIG welding is suitable for standard flat-wire terminals, while laser welding is suitable for both standard terminals and fine mini-pin terminals.
Within the production line, this station is positioned downstream of the wire-twisting machine and upstream of the electrical performance testing station.
The product is compatible with stators featuring an outer diameter of 100–500mm, flat-wire widths of 2–6mm, and mini-pin dimensions of ≤4mm.
Key Functions
Automatically clamps and positions the stator; a SCARA robot rapidly maneuvers the welding torch/laser head to each specific welding point;
Real-time monitoring of welding process parameters;
Water-cooling unit ensures thermal stability during operation;
Fume extraction and purification system collects welding fumes and dust;
Optional visual inspection system for weld points;
MES interface for data uploading;
One-touch recipe recall to facilitate rapid model changeovers.
Core Features (General)
1. High Speed & High Throughput: TIG welding cycle time is ≤2 seconds per point; laser welding cycle time is ≤1.5 seconds per point.
2. Rapid Robotic Positioning: SCARA robot enables rapid and precise positioning across multiple welding points.
3. Comprehensive Auxiliary Systems: Includes both a water-cooling unit and a fume extraction/purification system.
4. Intelligent Model Changeover: One-touch recipe recall enables model changeovers in ≤5 minutes.
5. Data Traceability: TIG welding supports MES monitoring; laser welding offers optional power monitoring capabilities.
TIG Welding Features
High weld strength; pull-out force ≥ 500 N;
Full, robust weld spots; suitable for thicker flat wires and high-stress operating conditions.
Laser Welding Features
Standard configuration: 4 + 2 kW (6 kW total); Upgraded configuration: 2 + 4 kW (6 kW total); enables deep-penetration welding;
Significant advantages for mini-pins (≤ 4 mm); pull-out force ≥ 300 N after deep-penetration welding;
Smooth weld spots; minimal heat-affected zone (HAZ).
Equipment Dimensions (L × W × H): 3.5 m × 2.2 m × 2.2 m (Typical)
TIG Welding Cycle Time (per point): ≤ 2.0 s
Laser Welding Cycle Time (per point): ≤ 0.3 s
TIG Welding Pull-out Force: ≥ 500 N
Laser Welding Deep-Penetration Pull-out Force (Mini-pin): ≥ 300 N
Total Laser Power: 6 kW (4+2 or 2+4 configuration)
Deep-Penetration Welding Capability: Supported; suitable for mini-pins (≤ 4 mm)
Robot Type: SCARA robot; rapid positioning/indexing
Auxiliary Systems: Water chiller + Dust extraction and purification system
Compatible Stator Outer Diameter: 100 – 500 mm
Compatible Flat Wire Dimensions: Width 2–6 mm, Thickness 1–3 mm; Mini-pin ≤ 4 mm
Model Changeover Method: One-touch recipe recall; changeover time ≤ 5 minutes
MES Monitoring: Included for TIG welding; Optional for Laser welding
Power Supply: 380 V / 50 Hz
Air Supply: 0.5 – 0.7 MPa
Equipment Weight: Approx. 4.5 tons (TIG) / Approx. 5.0 tons (Laser)
Safety Standards: CE Certified
