en.Wedoany.com Reported - TRUMPF has introduced a new laser welding solution for the production of electric vehicle electronics, replacing traditional screw connection processes. This solution directly welds copper conductors to copper busbars, enabling highly automated mass production. Liu Yuan, Senior Manager of Laser Application R&D at TRUMPF, stated that the precise synergy between laser technology, sensor technology, artificial intelligence, and data processing is key to ensuring an efficient and robust production process.
This solution is primarily used in the manufacturing of voltage distributors for electric vehicles and plug-in hybrid electric vehicles. These components distribute power from the vehicle's high-voltage battery to electrical devices such as the electric motor and lighting systems. Traditional mechanical screw connections require multiple complex steps and are susceptible to operational vibrations, leading to increased contact resistance, energy loss, and additional heat generation, thereby reducing system efficiency. The new laser welding process creates low-resistance welded joints, enhancing the efficiency of automotive electronics.
The core technology of this solution involves the synergy of laser, sensor technology, and AI. An AI image processing system identifies parts and positions the laser beam with pixel-level precision, while a 9 kW high-power fiber laser completes the copper chain welding. During the welding process, an Optical Coherence Tomography (OCT) system monitors the welding depth in real time to prevent complete penetration of the components. After welding, a camera-based system combined with AI recognition technology inspects weld quality, achieving high-precision automatic judgment with only a small number of training samples. All process steps are completed within a single laser workstation, with part identification and laser beam positioning completed in milliseconds. According to TRUMPF's Chung, a single process cycle takes less than one second, fully meeting the demands of industrial high-yield mass production, with the goal of achieving real-time, complete control of the process flow without slowing down production. The 9 kW fiber laser can weld millimeter-thick copper materials at high speed and with high reliability; for larger cross-sections, users can choose TRUMPF's more powerful laser products.
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