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Electric Motor ‘Hairpin’ Processing Using Laser

Electric Motor ‘Hairpin’ Processing Using Laser

Laser technology provides a high level of flexibility and quality when processing hairpins for the electric motors. Article by TRUMPF.

(Above, left) Hairpin with PAI coating after blast off process. High edge quality and low pulse overlap as well as line overlap. (Above, right) A row of single pulses. (Bottom) Surface after ablation with blast off process. Single spots are visible. This can be reduced by using repetitions with a higher frequency and higher line overlap after decoating.

Nowadays, manufacturers of electric motors are also looking for more productive processes for volume quantities, with the same high-quality requirements when it comes to the welding result. An important impetus here is achieving a higher degree of automation to be able to produce higher quantities.

One method in the construction of stators has therefore largely prevailed: Instead of winding copper wire around the individual stator grooves, as was often the case before, manufacturers have started embedding rectangular copper rods—called “hairpins” due to their shape—into the entire groove using compressed air. The typical edge lengths of the rectangular cross section of the hairpins is between 2 and 4 mm. The process achieves higher process speeds and can easily be automated. As the hairpins are stiffer than round wires, their alignment in the motor can be better controlled. The larger fill factor also results in a higher thermal load capacity, and higher motor power.

The copper rods are coated with an insulating layer, which requires ablation at both ends locally—called hairpin stripping—to enable contacting. Pulsed laser processing is suitable here to strip the hairpins. Compared to mechanical processes, such as planing and milling, laser processing is up to 80 percent more productive. Once the hairpins have been embedded in the grooves, protruding ends on the top and bottom of the stator are twisted together using a fixture (necking) or fixed in place, and then welded for contacting. The ends are not always ideally aligned to each other, however. If you use automated remote welding, a camera-based sensor system integrated in the laser optics helps achieve a reliable and reproducible result, and therefore the highest possible current flow.

Stripping of Hairpins

Common insulating layers for copper hairpins are polyamide-imides (PAI), polyether ether ketone (PEEK), and polyamide-imides with polyimide foil (PAI+FEP).

In the past, PAI coatings were almost exclusively prevalent in the industry, but we are now seeing a tendency towards a steady increase in PEEK and PAI+FEP. However, PAI coatings still have, and are likely to have in the future, the largest share by far.

All of these insulation coatings can be burnt away from the copper quickly and in a targeted manner using laser pulse processing. The laser light couples into the insulating layer, heats it up, and burns it off. PEEK behaves as a volume absorber for laser light, anyway; for PAI and PAI+FEP, it is recommended that the first run over is used to carbonize the material in order to increase the absorption. The copper discolours due to the heat influence during laser ablation. This is not relevant for the further processing, however, as the structure of the copper is not changed. Burrs also form at the boundaries to the coated copper, which, in unfavourable circumstances, could lead to the burr becoming stuck on a surrounding component or fixture. The formation of burrs and edges can be optimized, however, through reworking using another femtosecond-pulsed laser.

Hairpin stripping can be done with different types of TRUMPF ns laser. Most common is the TruMicro 7000 series with a laser power of up to 2 kW (pulse energy 100 mJ) at a pulse repetition rate of 5 to 250 kHz and a pulse duration of 30 ns.

There are two stripping processes for the hairpins depending on the coating type: 

  • For coatings which are transparent to the laser a “blast off” process can be used. 
  • For non-transparent coatings an evaporation process is needed. 

Click here to read the full version of the article in the April 2020 issue of Asia Pacific Metalworking Equipment News.

 

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AMADA WELD TECH Announces New Company Name

AMADA WELD TECH Announces New Company Name

AMADA WELD TECH, formerly AMADA MIYACHI EUROPE has announced its new company name, effective April 1, 2020. This name change will allow the company to present themselves as an AMADA group company with the highest experience in welding and associated precision technologies.

The new name will soon appear on all mailings, invoices, packaging, and other promotional materials.

The company itself remains the same, simply under a new name. The same commitment to customers, products, quality of service, and employees will continue unchanged. The extensive range of equipment and systems in Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding will remain at the highest quality that our customers have come to know and expect.

AMADA WELD TECH requests that customers update records accordingly and address all future business correspondence to the new name, AMADA WELD TECH.

 

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PTG Introduces Powerstir Dual Weld-Head Friction Stir Welding For Electric Vehicle OEMs

PTG Introduces Powerstir Dual Weld-Head Friction Stir Welding For Electric Vehicle OEMs

UK-based Precision Technologies Group (PTG) has introduced a number of dual weld-head FSW models specifically for use in the volume production of automotive battery tray floor assemblies from extruded aluminium panels.

Ensuring a tight weld-flatness tolerance

PTG has been assisting automotive OEMs in producing lightweight, robust and aesthetic components for battery electric vehicles (BEV) and plug-in hybrid electric vehicles (PHEV). Aimed directly at manufacturers of skateboard chassis structures, the dual weld-head process developed by PTG ensures that a tight weld-flatness tolerance is achieved during battery tray floor construction.

A tight weld-flatness tolerance is essential to ensure that each battery cell sits perfectly level within its housing. PTG Powerstir dual weld-head FSW machines provide an even and stable welding process – something that is achieved thanks to the company’s unique ‘matched’ dual-force control systems and balanced upper and lower head welding parameters. The result is exceptionally stable friction stir welding by both the upper and lower weld heads, producing matched weld seams with balanced heat input. This, in turn, minimises post-weld distortion and equips each welded assembly with a significantly improved flatness tolerance when compared to existing conventional single-side FSW techniques.

High-output production cell

As aluminium extrusion lines usually produce panels of 300 mm to 600 mm wide, PTG has also developed a fully automated, high-output Powerstir FSW production cell for the rapid friction stir welding of multiple extrusions, to create single structures for fabrication into battery tray floors. These structures are typically up to 2.4 metres wide.

“Our dual weld-head FSW technologies, whereby both sides of an extrusion are welded simultaneously, not only remove the time-consuming process of lifting and turning extrusions between welds, but also allow for equal heat dispersion which results in minimal distortion,” comments PTG Powerstir Regional Sales Director, Mark Curran.

In the PTG Powerstir dual weld-head FSW process, typically four to 12 individual child-part extrusions are brought together for assembly. Following gantry loading, each extrusion is automatically positioned and clamped ready for friction stir welding, after which the partially completed vehicle component is automatically repositioned, ready for the next panel to be welded in place.

Reduced wall thickness

“In addition to providing automotive OEMs with a state-of-the-art means of joining metals and achieving extremely high-strength results, it is also important to consider that in many instances, the use of friction stir welding also allows for reduced wall thickness – an important aspect in reducing vehicle weight,” adds Mark Curran. “As the friction stir welding process generates very little heat, the crystalline structure of the metal remains unchanged, retaining its original strength. There is no need for inert gas, no need for heat-treating post weld, and no requirement for additional surface finishing.”

High-strength joints that are virtually defect free

Friction stir welding combines frictional heat with precisely controlled forging pressure to produce extremely high-strength joints that are virtually defect free. Due to the very low welding temperature, mechanical distortion is practically eliminated, with minimal Heat Affected Zone (HAZ) and an excellent surface finish. Friction stir welding transforms the parent metal from a solid to a plasticised state. This occurs during a process that involves mechanically stirring the materials to be joined together, to form a high integrity, full-penetration welded joint. The Powerstir FSW process is effective on flat plates, cylindrical components and even on parts of irregular thickness. Although used primarily for joining aluminium, the Powerstir process can also be applied to magnesium, copper, titanium and steel alloys.

 

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Toshiba Spot Welding Inspection Robots Revolutionises The Automotive Industry

Toshiba Spot Welding Inspection Robots Revolutionises The Automotive Industry

Strength tests on samples taken from parts consisting of 4,000-5,000 spot welds on a vehicle are an indispensable part of the automobile manufacturing process, which is costly and time and labour-intensive. Toshiba has developed a system that allows testing to be carried out automatically by robots in a non-destructive manner, and is poised to spark a massive revolution in manufacturing in the automotive industry.

As cars become lighter and stronger in recent years, high-strength steel sheets known as ‘high-tension materials’ are increasingly being used. The properties of these high-tension materials make it hard for chisels to be inserted and returned to normal once they are deformed. The welded spots are often destroyed in the course of inspection.

Tapping on technology for medical use and power generation plants, Toshiba developed an ultrasonic testing device known as Matrixeye, the world’s first 3D SAFT (Synthetic Aperture Focusing technique) inspection equipment with phased array function. Matrixeye allows welds to be inspected non-destructively and inspection to be performed automatically by robots.

The challenge in non-destructive inspection technology was creating structures for automating spot welding inspections through robot control. The tilt estimation engine is a new technology that automatically adjusts the measurement angle of the inspection probe. Based on the ultrasound reflection data measured by the Matrixeye, it estimates the tilt of the welded part and then a robot automatically corrects the angle of the inspection probe. Through this, inspection time is shrunk from 30-40 seconds for human beings to approximately seven seconds.

As the concept of Mobility-as-a-Service (MaaS) develops in the future, the number of public vehicles will most likely increase as well. To support this coming era, factories will be expected to put structures in place to enable them to provide high-quality vehicles in a speedy fashion. Toshiba is carrying out verification tests with a goal of launching this spot welding inspection technology within a year, and for the technology to be adopted in other fields of manufacturing too.

 

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Amada Miyachi Europe: MM-L300A Laser Weld Monitor

Amada Miyachi Europe: MM-L300A Laser Weld Monitor

Amada Miyachi Europe announces the availability of the new MM-L300A Laser Weld Monitor. The compact MM-L300A is designed to detect welding defects and errors such as gaps between parts, missing parts, weld depth over-penetration, incorrect focus point and cover gas absence. It is providing operators feedback on the resultant laser weld quality. The compact, lightweight unit supports laser welding technologies for spot or seam welds.

This high-accuracy monitor is ideal for both process development and quality control for laser welding applications. The MM-L300A indicates weld quality by detecting and recording a thermal signal from the area of laser interaction and converting this into a graphical waveform. Part of the intelligence of this third-generation process monitor is that not only absolute max/min limits can be set but also value envelopes can be drawn around the waveform. Once the limits are determined, the unit compares a new weld waveform in real time to identify a good or bad weld. Providing high temporal resolution – down to 1 microsecond – the MM-L300A, with the SU-N300A dedicated thermal sensor, enables precision monitoring of both continuous wave and pulsed laser processes.

The MM-L300A features easy-to-use software for simple sensor configuration, waveform envelope limit set-up, and real-time or saved waveform analysis on Windows PCs. Additionally, machine-selectable setup schedules enable the unit to monitor different welding conditions. The compact, 3 kg (7 lb) unit reduces set-up space when integrated into a production line or used in a laboratory environment. The sensor can be mounted either on the optical axis of the laser beam trajectory or in an off-axis position.

 

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Use Of Durable Consumables In Robotic Welding Torches Reduces Downtime Costs

Use Of Durable Consumables In Robotic Welding Torches Reduces Downtime Costs

In terms of revenue, the global welding torch and wear parts market is estimated to expand at a CAGR of four percent during the forecast period, according to report by Transparency Market Research.

In this market report, study predicts that, increase in the production of passenger and commercial vehicles is anticipated to boost the welding torch and wear parts market during the forecast period. Rising disposable income and increasing road connectivity are some of the prime factors responsible for the growth of the welding torch and wear parts market. As per statistics by the International Automotive Industry, in 2017, passenger car production grew by approximately 2.4 percent as compared to the previous year.

Additionally, growth in construction and manufacturing industries, worldwide, is further anticipated to fuel the growth of the welding torch and wear parts market. Construction and manufacturing industries are anticipated to drive the growth of the welding torch and wear parts market due to extensive application of submerged arc, metal active gas, as well as manual metal.

However, unskilled labor is a key restraining factor for the growth of the welding torch and wear parts market, despite advancements in technologies to enhance efficiencies in welding processes, which has led to the sophistication of welding torches.

Nevertheless, increasing opportunities in untapped markets are anticipated to boost the growth of the welding torch and wear parts market. Regions such as Asia Pacific, Middle East & Africa, and South America are experiencing robust demand for welding torch and wear parts, owing to increasing economic growth in the last couple of years. Increase in disposable income, and growth in industries such as construction, manufacturing, as well as sports is augmenting the demand for welding torch and wear parts.

In terms of process under the welding torch and wear parts market, the MIG/MAG process accounted for substantial share as compared to the TIG and plasma processes. MIG/MAG processes are the most common and basic welding processes in the welding industry. The MIG welding process has wide application across aluminum, stainless steel, and steel sectors as compared to the TIG process that is ideally used for thinner surface metals.

Based on cooling method, the gas-cooled segment dominated the welding torches and wear parts market. Gas-cooled welding torches have numerous applications in lower amperages, which makes them a better option for welders as compared to water-cooled torches.

Manual welding torches acquired substantial share in 2018, owing to their extensive application in the welding industry. In terms of end-use industry, heavy the equipment manufacturing and construction industry dominated the global welding torch and wear parts market, owing to the wide-spread application of welding torches as compared to other segments.

The offline segment acquired substantial market share due to the strong network of suppliers and distributors, worldwide.

Welding Torch and Wear Parts Market: Prominent Regions

Asia Pacific dominated the global welding torch and wear parts market, followed by North America. The dominance of Asia Pacific can be attributed to the presence of strong end-use industries. Additionally, the region is one of the manufacturing hubs of the world, which helps in its dominance of the global welding torch and wear parts market.

 

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Automation To Take Center Stage In The Global Welding Equipment Market

Automation To Take Center Stage In The Global Welding Equipment Market

According to report by Persistence Market Research, the global welding equipment market expects the market to witness strong growth during the forecast period 2017-2024. The global market for welding equipment is estimated to reach close to US$ 19,200 Million revenue.

The manufacturing and fabrication industries are evolving constantly. This is resulting in the companies seeking out new technologies to stay ahead of competitors. Use of new materials in various industries is driving the need for welding automation. Companies are also moving towards acquiring new solutions to offer quality product and increase productivity. In response to this, welding equipment manufacturers are bringing in advanced technologies to help companies’ better serve their customers. Manufacturers are developing welding solutions that can serve both small scale and large-scale companies. Modified short-circuit MIG is being integrated into welding machines, ensuring better control and to create high-quality and uniform welds.

New materials such as high strength steels, advanced high strength steels, and increased use of stainless steel and aluminum in fabrications are creating the demand for new welding technology as per the material being used. Hence, a welding system for specific materials is also being developed by manufacturers in the global welding equipment market. Rising trend towards automation is also resulting in the development automated welding equipment for wide range of application. Information management system for welding is also gaining popularity. This system collects and provides information arc-on time, and performance based on voltage and amperage. This help companies to collect data on the performance of welding in real-time and track both quality and productivity.

 

Arc Welding Technology to Lead the Global Welding Equipment Market

Based on the welding technology, arc welding technology is expected to see a significant growth in the market. By the end of 2024, arc welding technology is projected to surpass US$ 8,500 Million in terms of revenue. Meanwhile, resistance welding is also projected to witness impressive growth during 2017-2024.

On the basis of a level of automation, compared to the manual welding equipment, automatic welding equipment is likely to register the highest growth during 2017-2024. Automatic welding equipment is expected to exceed US$ 13,000 Million revenue by 2024 end.

Based on the application of welding equipment, automotive & transportation sector is expected to gain maximum traction in the global market for welding equipment. Towards 2024 end, the automotive & transportation sector is estimated to reach nearly US$ 3,800 Million revenue.

Asia Pacific to Lead the Global Welding Equipment Market between 2017 and 2024

Asia Pacific is likely to dominate the global market for welding equipment during the forecast period. Asia Pacific is estimated to reach close to US$ 6,600 Million in terms of revenue. Increasing infrastructure and construction activities in the countries like India and China are driving the demand for welding equipment. Moreover, the automotive industry in Asia Pacific is also witnessing a substantial growth, thereby, fueling the demand for welding equipment. Growth in the steel industry owing to the increasing demand for steel in for product manufacturing in different industries is resulting in the growth of the welding equipment market in the region.

Key Players in the Global Welding Equipment Market

Some of the prominent players active in the global market for welding equipment are DAIHEN Corporation, Colfax Corporation, The Lincoln Electric Company, Fronius International GmbH, Obara Corporation, voestalpine AG, Arcon Welding Equipment, Panasonic Corporation, Sonics & Materials, Inc., Rofin-Sinar Technologies, Nelson Stud Welding (Doncasters Group, Ltd.), Amada Miyachi, Inc., and Illinois Tool Works, Inc.

 

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LP-XQ Control By EWM: User-Friendly And Convenient

LP-XQ Control By EWM: User-Friendly And Convenient

EWM has expanded the LP-XQ control for the Titan XQ puls MIG/MAG multi-process welding machine with additional features, making the welder’s job much easier. The new control makes switching between EWM welding processes quick and easy. The five favourite buttons are a particular plus. These allow the welder and welding coordination personnel to save the individual settings for various recurring welding tasks and quickly load them up later with the press of a button, making the machine easier to use, saving time and increasing process efficiency.

The LP-XQ control comes with a new quick selection feature to make set-up and work a breeze: switching between the MIG/MAG processes MIG/MAG Standard, forceArc, wiredArc, rootArc and coldArc is now easier than ever with the process switch button. You can also quickly switch between standard JOBs, pulse and Positionweld. The optimum characteristics are always adapted automatically to the specified basic settings such as welding consumable material and its diameter, or the gas used.

Process optimisation with favourite lists

Recurring settings can be saved with the LP-XQ control. If the welder has found the optimum parameters for his/her welding task, he/she can save these individual settings using a total of five favourite buttons. This allows the welder to quickly load up these settings again for recurring welding jobs.

Secure qualified welding processes

In addition, favourite lists can help to secure qualified welding processes. Welding coordination personnel can define the parameters for a qualified welding process on one of the favourite buttons. When locked, the welder can only load the preset welding parameters, preventing any deviation. Activating correction mode allows the welder to adjust the parameters of the preset favourites in the set tolerance range. Another great feature of the new LP-XQ control is the visual display of arc dynamics. This uses signal lights to clearly display whether the operator has made a correction to the arc hardness.

Another building block for future welding tasks

EWM completes its Welding 4.0 product portfolio with the new control. All innovative EWM welding processes are included in the Titan XQ puls MIG/MAG multi-process welding machine as standard and can be selected using the control. With the Welding 4.0 welding management system, ewm Xnet 2.0, EWM delivers an optimised work environment to enable welders to perfectly carry out various welding tasks – whether for thin or thick plate applications, filler, final or root passes, or in positional welding.

 

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OMRON Releases E2EW Series Durable Full Metal Proximity Sensor
 

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OMRON Releases E2EW Series Durable Full Metal Proximity Sensor

OMRON Releases E2EW Series Durable Full Metal Proximity Sensor

OMRON Corporation has launched the E2EW Series Full Metal Proximity Sensors, which boast the world’s longest sensing distances. The sensors enabled both detection stability for different material components and durability with the full metal body. They help enhance productivity in the automotive industry, where downtime leads large production opportunity losses, by reducing risks of sudden stoppages due to sensors occurred in the welding processes for automobiles.

Automotive industry needs lighter weight of automobiles in accordance with the trend of electric vehicles and low fuel consumption, encouraging the material change in automotive components from iron to aluminum. This will increase mixed production lines containing iron and aluminum. Full metal proximity sensors are mainly used in harsh welding processes. However, previous full metal proximity sensors have short sensing distances. In particular, the sensing distance for aluminum is shorter than the one for iron. Therefore, higher accuracy is required for installing proximity sensors for aluminum than iron, making the design, start-up, and maintenance of production lines complicated. With skilled labor shortages becoming severer, however, demand is growing for ways to maintain and enhance facility operation rates without relying on human experience or skills.

The sensing distance are approximately twice as long as previous models for iron, and six times as long as previous models for aluminum, meaning equivalent sensing distances to detect iron and aluminum components. In addition, OMRON’s technologies prevents coating abrasion which allows 60 times longer-lasting spatter resistance than previous models. The E2EW Sensors with its durable body and long sensing distance increase sensor installation flexibility, and they help enhance productivity by streamlining production lines which require skills from the start-up, operation, to maintenance.

 

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Nissin Electric To Move Production From Thailand And Vietnam To Myanmar

Nissin Electric To Move Production From Thailand And Vietnam To Myanmar

Nissin Electric Company of Japan will be opening a new factory in Myanmar which would start operations in March 2020, through a joint venture with Hosoda Holdings. The company is relocating some of its production processes from its plant in Thailand and Vietnam to this new plant in order to cut labour costs.

Nissin Electric currently manufactures all of its products in Thailand and Vietnam, with products accounting to 60 percent and 40 percent of profits respectively. The factories near Bangkok and Hanoi are undertaking sheet metal welding, cutting and surface treatment processes for industrial equipment and parts.

The new Myanmar plant will make electrical equipment and take on contract manufacturing of such machines and parts. The company will also be moving some metal parts manufacturing processes like mounting of device frames and welding to its Myanmar factory.

 

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