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Laser welding solution for copper connections in power electronics
TRUMPF introduces AI-assisted laser welding for copper conductors and busbars, improving efficiency, reliability and series production of electric vehicle power electronics.
www.trumpf.com
TRUMPF’s new laser solution enables more efficient power distributors in electric vehicles. (Image: TRUMPF)
Precision Fusion via Fiber Laser and Sensor Integration
The system will replace traditional mechanical screw connections with firmly fused joints, which exhibit lower electrical resistance. Unlike mechanical connections, these laser-welded joints are resistant to vibrations and prevent the energy losses and heat generation associated with the higher resistance of mechanical fasteners.
The technical workflow is managed within a single laser station through the synchronization of several hardware and software layers:
- Positioning: An AI-supported image processing system identifies the copper components and positions the laser beam with pixel-level precision.
- Welding: A 9 kW fiber laser executes the weld at high speed, capable of penetrating copper to a depth of several millimeters.
- Monitoring: An Optical Coherence Tomography (OCT) system provides real-time monitoring of the welding depth to ensure structural integrity and prevent burn-through.
AI-Driven Quality Assurance and Process Speed
Artificial intelligence is utilized to maintain stability during high-productivity series production. The system will employ AI for both component recognition and post-weld quality assessment. By utilizing a limited set of training images, the AI identifies seam defects and ensures every component meets rigorous safety standards for high-voltage applications.
The entire technical sequence—including recognition, positioning, welding, and quality control—will be completed in under one second. This rapid cycle time is designed for seamless integration into high-volume manufacturing lines without disrupting the production flow. For manufacturers processing larger cross-sections, the architecture supports scaling to more powerful TRUMPF laser drivelines to maintain speed across various conductor thicknesses.
Optimization of the Automotive Digital Supply Chain
By consolidating multiple mechanical assembly steps into a single automated laser process, the solution reduces the potential for manual assembly errors. This transition supports a more robust digital supply chain for EV manufacturers, providing instantaneous traceability and process data for each welded joint. The removal of mechanical fasteners also simplifies the bill of materials and reduces the overall weight of the voltage distribution unit.
Edited by Romila DSilva, Induportals Editor, with AI assistance.
Artificial intelligence is utilized to maintain stability during high-productivity series production. The system will employ AI for both component recognition and post-weld quality assessment. By utilizing a limited set of training images, the AI identifies seam defects and ensures every component meets rigorous safety standards for high-voltage applications.
The entire technical sequence—including recognition, positioning, welding, and quality control—will be completed in under one second. This rapid cycle time is designed for seamless integration into high-volume manufacturing lines without disrupting the production flow. For manufacturers processing larger cross-sections, the architecture supports scaling to more powerful TRUMPF laser drivelines to maintain speed across various conductor thicknesses.
Optimization of the Automotive Digital Supply Chain
By consolidating multiple mechanical assembly steps into a single automated laser process, the solution reduces the potential for manual assembly errors. This transition supports a more robust digital supply chain for EV manufacturers, providing instantaneous traceability and process data for each welded joint. The removal of mechanical fasteners also simplifies the bill of materials and reduces the overall weight of the voltage distribution unit.
Edited by Romila DSilva, Induportals Editor, with AI assistance.
