Welding, as one of the core processes on the hairpin E-motor stator production line for NEV, mainly includes laser welding and TIG welding. However, both of them have their own limitations: laser welding is not only high in cost, but also requires quite accurate welds positions in practical use, and has high requirements for copper wire cross-section status. Although TIG welding has good compatibility, and is able to achieve splash-free welding with low cost, however the welding time for each spot is about 1.8 seconds and the efficiency is relatively low.

In order to improve efficiency, reduce cost, and achieve better welding effects, Haosen E-motor R&D team innovatively upgraded TIG welding, thus a multi-welder continuous welding technology was developed and released.

This technology can be applied to copper wire with regular size currently in use, with two or more welding guns arcing simultaneously, and welding one circle of spots at a time in continuous pulse welding. The advantages are listed as below:

1.Improved welding efficiency: continuous welding can be carried out after arcing successfully. Taking each stator with 8 layers and 54 slots as an example, it takes 102.8 seconds for two welding guns to finish 216 points, which improves the efficiency by more than 50% compared to TIG welding. The speed of rotary welding can be adjusted according to the situation.

2.Simple structure and low cost: compared to traditional TIG welding, this technology has no special hardware additions and reduces the losses caused by frequent arcing of tungsten electrodes, prolongs its service life, and also reduces the extra time for tungsten electrodes replacement and grinding.

3.Improved device stability: one-time arc welding can avoid missing caused by occasional arcing failure, prolong the service life of tungsten electrodes, and reduce position deviation caused by frequent changing of points, which will influence the welding effects.

The multi-welder continuous welding technology will be optimized and tested by the technical team before being promoted to the market, making new contributions to the improvement of industrial manufacturing level. Haosen is devoted to enhance the automation, digitization, flexibility, intelligence, and greenization of the whole industry. In the future, Haosen will take technology as the core and market demand as the guide, will continue to promote technological R&D innovation and market transformation, and will inject a continuous stream of kinetic energy into the healthy development of the new energy industry.