Abstract
Electric vehicles are recently prosperous due to decarbonization and electrification in transportation. However, manufacturing their motor windings with stable high quality is challenging, especially in hairpin laser welding. This study introduces a novel interpolator using polar angles as primary indicators, achieving process flexibility and high-performance synchronization between positions and powers. The interpolator is well-designed theoretically, more advantageous compared to those traditional ones in hairpin welding, while also compatible with them. Four speed planning modes are available depending on whether the speed is angular or linear, constant or variable. Additionally, energy distributions based on polar-angle power profiles can be adjusted and optimized according to practicality. Both the speed and power profiles, as two critical welding parameters, facilitate precise in-process modification dramatically. In the end, two groups of comparative experiments are performed to positively validate the interpolator’s feasibility and effectivity to improve weld quality. Significantly, this work establishes a fundamental framework linking diverse paths and hairpin welding processes which is essential for weld quality control and optimization.
Similar content being viewed by others
References
Soltani M, Nuzzo S, Barater D, Di Nardo M (2023) Performance analysis of a permanent magnet motor with continuous hairpin winding. 2023 IEEE Workshop on Electrical machines Design, Control and diagnosis (WEMDCD), IEEE. 1–6. https://doi.org/10.1109/WEMDCD55819.2023.10110948
Zou TJ, Gerada D, La Rocca A, Moslemin M, Cairns A, Cui MM, Bardalai A, Zhang FY, Gerada C (2022) A comprehensive design guideline of hairpin windings for high power density electric vehicle traction motors. Ieee T Transp Electr 8(3):3578–3593. https://doi.org/10.1109/TTE.2022.3149786
Wirth F, Nguyen C, Hofmann J, Fleischer J (2020) Characterization of rectangular copper wire forming properties and derivation of control concepts for the kinematic bending of hairpin coils. Procedia Manuf 47:678–685. https://doi.org/10.1016/j.promfg.2020.04.209
Nuzzo S, Barater D, Gerada C, Vai P (2022) Hairpin windings: an opportunity for next-generation e-motors in transportation. Ieee Ind Electron M 16:52–59. https://doi.org/10.1109/MIE.2021.3106571
Glaessel T, Seefried J, Franke J (2017) Challenges in the manufacturing of hairpin windings and application opportunities of infrared lasers for the contacting process. 2017 7th International Electric Drives Production Conference (EDPC), IEEE, pp 64–70. https://doi.org/10.1109/EDPC.2017.8328150
Petri T, Keller M, Parspour N (2022) The insulation resilience of inverter-fed low voltage traction machines: review, challenges, and opportunities. Ieee Access 10:104023–104049. https://doi.org/10.1109/ACCESS.2022.3210348
Agapiou JS, Perry TA (2013) Resistance mash welding for joining of copper conductors for electric motors. J Manuf Process 15(4):549–557. https://doi.org/10.1016/j.jmapro.2013.06.014
Tóth T, Hensel J, Thiemer S, Sieber P, Dilger K (2021) Electron beam welding of rectangular copper wires applied in electrical drives. Weld World 65(11):2077–2091. https://doi.org/10.1007/s40194-021-01158-4
Hartung J, Jahn A, Bocksrocker O, Heizmann M (2021) Camera-based in-process quality measurement of hairpin welding. Appl Sci-Basel 11(21):10375. https://doi.org/10.3390/app112110375
Zhang Y, Huangfu YX, Ziada Y, Habibi S (2023) Efficient hairpin winding fault detection using impedance measurements. Ieee Access 11:92838–92846. https://doi.org/10.1109/ACCESS.2023.3309247
Glaessel T, Seefried J, Masuch M, Riedel A, Mayr A, Kuehl A, Franke J Process reliable laser welding of hairpin windings for automotive traction drives. 2019 International Conference on Engineering, Science, and, Applications I (2019) (ICESI), IEEE, pp 1–6. https://doi.org/10.1109/ICESI.2019.8863004
Dimatteo V, Ascari A, Faverzani P, Poggio L, Fortunato A (2021) The effect of process parameters on the morphology, mechanical strength and electrical resistance of Cw laser-welded pure copper hairpins. J Manuf Process 62:450–457. https://doi.org/10.1016/j.jmapro.2020.12.018
Omlor M, Petrich T, Blumenstein C, Berndt C, Dilger K (2022) Method for analyzing welding speed and beam deflection and its effect on laser welded hairpin windings for electric drives. Procedia CIRP 111:551–556. https://doi.org/10.1016/j.procir.2022.08.148
Kampker A, Kawollek S, Dorn B, Stack C (2021) Initial strength joining of flat conductor-based shaped coils for optimised laser welding preparation in hairpin technology. 2021 11th International Electric Drives Production Conference (EDPC), IEEE, pp 1–9. https://doi.org/10.1109/EDPC53547.2021.9684220
Will T, Müller J, Müller R, Hölbling C, Goth C, Schmidt M (2023) Prediction of electrical resistance of laser-welded copper pin-pairs with surface topographical information from inline post-process observation by optical coherence tomography. Int J Adv Manuf Tech 125:1955–1963. https://doi.org/10.1007/s00170-022-10796-x
Kampker A, Heimes HH, Dorn B, Brans F, Hartmann S, Schaffrath M (2022) Effects of the reduction of the copper wire cross-section on the welding process in the manufacturing of hairpin stators for electric traction motors. 2022 12th International Electric Drives Production Conference (EDPC), IEEE, pp 1–9. https://doi.org/10.1109/EDPC56367.2022.10019755
Omlor M, Reinheimer EN, Butzmann T, Dilger K (2023) Investigations on the formation of pores during laser beam welding of hairpin windings using a high-speed x-ray imaging system. J Laser Appl 35(3):32010. https://doi.org/10.2351/7.0000983
Baader M, Mayr A, Raffin T, Selzam J, Kuhl A, Franke J (2021) Potentials of optical coherence tomography for process monitoring in laser welding of hairpin windings. 2021 11th International Electric Drives Production Conference (EDPC), IEEE, pp 1–10. https://doi.org/10.1109/EDPC53547.2021.9684210
Omlor M, Seitz N, Butzmann T, Petrich T, Gräf R, Hesse AC, Dilger K (2023) Quality characteristics and analysis of input parameters on laser beam welding of hairpin windings in electric drives. Weld World 67:1491–1508. https://doi.org/10.1007/s40194-023-01500-y
Auwal ST, Ramesh S, Yusof F, Manladan SM (2018) A review on laser beam welding of copper alloys. Int J Adv Manuf Tech 96:475–490. https://doi.org/10.1007/s00170-017-1566-5
Miyagi M, Zhang XD (2015) Investigation of laser welding phenomena of pure copper by x-ray observation system. J Laser Appl 27(4):42005. https://doi.org/10.2351/1.4927609
Schricker K, Schmidt L, Friedmann H, Diegel C, Seibold M, Hellwig P, Fröhlich F, Bergmann JP, Nagel F, Kallage P, Rack A, Requardt H, Chen Y (2022) Characterization of keyhole dynamics in laser welding of copper by means of high-speed synchrotron x-ray imaging. Proc CIRP 111:501–506. https://doi.org/10.1016/j.procir.2022.08.079
Chen HC, Bi GJ, Nai MLS, Wei J (2015) Enhanced welding efficiency in laser welding of highly reflective pure copper. J Mater Process Tech 216:287–293. https://doi.org/10.1016/j.jmatprotec.2014.09.020
Buser M, Onuseit V, Graf T (2021) Scan path strategy for laser processing of fragmented geometries. Opt Laser Eng 138:106412. https://doi.org/10.1016/j.optlaseng.2020.106412
Nieke S, Rauscher P, Hauptmann J, Schwarz T, Mende M (2021) Solution for real time sensor guided programmable logic controller of galvanometer scanners. J Laser Appl 33(4):42029. https://doi.org/10.2351/7.0000477
Wang ZM, Oliveira JP, Zeng Z, Bu XZ, Peng B, Shao XY (2019) Laser beam oscillating welding of 5a06 aluminum alloys: microstructure, porosity and mechanical properties. Opt Laser Technol 111:58–65. https://doi.org/10.1016/j.optlastec.2018.09.036
Sadeghian A, Nath S, Huang YZ, Matharu RS, Wadee N, Pembrey N, Waugh DG (2022) Quasi-continuous wave pulsed laser welding of copper lap joints using spatial beam oscillation. Micromachines-Basel 13(12):2092. https://doi.org/10.3390/mi13122092
Zhang MJ, Chen GY, Zhou Y, Li SC, Deng H (2013) Observation of spatter formation mechanisms in high-power fiber laser welding of thick plate. Appl Surf Sci 280:868–875. https://doi.org/10.1016/j.apsusc.2013.05.081
Wang L, Gao M, Zeng XY (2019) Experiment and prediction of Weld morphology for laser oscillating welding of aa6061 aluminium alloy. Sci Technol Weld Joi 24(4):334–341. https://doi.org/10.1080/13621718.2018.1551853
Yin YS, Zhang CR, Zhu TS, Qu LC, Chen G (2022) Development of a laser scanning machining system supporting on-the-fly machining and laser power follow-up adjustment. Materials 15(16):5479. https://doi.org/10.3390/ma15165479
Author information
Authors and Affiliations
Contributions
TZ: methodology, data curation, software, writing—original draft, validation, writing—review and editing. CZ: conceptualization, supervision, writing—review and editing. YY: data curation, visualization.
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Zhu, T., Zhang, C. & Yin, Y. A novel interpolator designed for laser scanning welding of hairpin windings in electric vehicle motors. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13917-w
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s00170-024-13917-w