E-Mobility Manufacturing Solutions
Partnering with manufacturers and their automation integrators to increase quality, improve production processes and lower overall production costs
Manufacturers of battery cells and modules, electric vehicles and energy storage systems come to IPG for flexible, reliable and productive laser-based manufacturing solutions. Covering the range of battery production steps from processing of electrode films, welding cells to busbars or the structural components of the battery trays, our technical leadership in the area of laser-material interactions allows us to provide industry-leading guidance and support to automotive manufacturers and their chosen production line integrators.
Whether it is the unmatched power levels of the pulsed foil cutting lasers, the unique capabilities of the adjustable mode beam lasers for spatter-free welding of copper and aluminum, or the patented real-time weld measurement technology; IPG is continually working to optimize laser materials processing capabilities to keep you ahead of rapidly evolving E-Mobility trends.
Speak to our E-Mobility Team
Laser processing in Li-ion cell manufacturing starts with the electrode films, with laser cutting and notching of the foils, drying the dielectric coatings, and pre-weld coating removal at weld sites. Lasers are essential in cell assembly, with processes for welding electrodes to contacts, securing vents and sealing the can-caps.
Solutions include high-power pulsed lasers and diode laser arrays for electrode processing, and adjustable mode beam (AMB) lasers for low porosity metal welding.
Interconnection of the individual cells into modules using high-conductivity busbars or lattices relies on rugged, reliable, low resistance electrical contacts. Compared to alternate technologies laser welding provides better electrical performance, and is significantly faster. For cylindrical cell batteries with thousands of connections, higher speed equates to significant production cost savings.
Solutions include AMB lasers and high-power scan heads for welding, with optional patented LDD real-time weld measurement for 100% inspection of the weld quality.
Building modules and battery packs generally involves two different types of processes. First, making electrical connections to increasingly thick conductors, frequently of dissimilar or coated materials. Second, closing the robust mechanical cases that enclose the electrical elements.
For many designs, the enclosed battery pack functions as a structural element in the vehicle, making high integrity, high strength welds a mandatory requirement.
Solutions include AMB lasers for low-porosity welding of copper connections and aluminum cases, high-power lasers and scanning heads for high-speed, on-the-fly case welding, and LDD real-time weld measurement and verification.
In addition to standard mechanical fabrication of motor body casings, E-Mobility has seen a rise in requirements for stripping insulation, and then welding, the hairpin conductors.
Solutions for insulation stripping are generally pulsed lasers combined with scanners that are integrated into the motor assembly tools. For hairpin welding, laser and scanners can be purchased individually, or as a combined Integrated Laser Welding System (ILWS) module, which includes a programmed controller and vision alignment system to make tooling and line integration even easier.
Battery control units and inverters typically require making electrical connections to dissimilar or coated metals, and case enclosures.
In addition to low electrical resistance joints, minimizing spatter during the welding process is important as the ejection of molten material from the weld pool causes weld porosity and creates electrically conductive debris potentially causing electrical defects.
AMB dual-beam lasers utilize the high power density of the single-mode core beam to initiate the weld and the enlarged ring beam to stabilize the weld pool, enabling reliable, high-speed processing.
Whether you need to demonstrate feasibility with laser processed parts, or just want to bounce design and implementation ideas off an experienced laser engineer – give us a call.
IPG is the world leader of fiber laser technology and experts in materials processing. It was what the company was founded on, and what drives everyone in the organization today. Our mission is to make laser processing the manufacturing technology of choice, and that relies on sharing the technical knowledge so customers can make a choice.
Call and talk to us, or better still, visit one of the 24 regional applications development sites to get the information you need.
E-Mobility solutions start from off the shelf laser and beam delivery products, and can include process development, integration support, integrated system programming, and turnkey laser processing modules and systems.
Find out how these can benefit your E-Mobility initiatives.
We offer a wide range of turnkey laser processing solutions for E-Mobility manufacturing applications. These systems are used in applications from process development and prototype part production through fully automated production.
These systems can typically accelerate the time to first deploy a laser manufacturing step as we provide the laser process development, component integration and software programming.
IPG has provided tens of thousands of custom laser solutions around the world, and we understand that every job is unique in its own way.
Let us help you design and implement your custom E-Mobility laser solution by drawing on our industry-leading laser materials processing and engineering expertise.