Newlas has developed a laser welding solution specifically for the laser welding of hire PIN motors. The solution includes a pre-welding recognition system and a post-welding quality inspection system that are compatible with I-pin, U-pin, Umini, and X-pin types of terminals.
The 2D camera and 3D camera are combined to capture the coordinates of the welding points and assign different process numbers to each Pin, which provides visual guidance for the welding process.
For X-pin type terminals, the solution includes precise and accurate positioning and detection systems to address issues such as unevenness of the terminal surface, gaps and misalignment.
The system uses a 2D camera to capture images and identify the welding points of I-pin, U-pin, Umini, and X-pin types of motors. It also controls the position of the welding head using visual algorithms to complete the recognition and guidance before welding.
- Product type: The whole area is divided into 8 ROI areas, 8 photos are taken, 4*6 points each time, a total of 192 solder joints
- Pre-weld positioning inspection: NewVison-2D/3D positioning inspection system
- Welding head: NewScan-2D/3D remote laser welding system
- Laser: RFL-ABP ring spot laser
- Post-weld quality inspection: NewQISys quality inspection system
- Total tempo: photography + welding tempo <35s
- The 3D vision system is used to detect X-pin joint assembly gaps, horizontal mis-alignments, deflection angles, vertical mis-alignments, etc.
I-pin/U-pin/Umini motor laser welding solution
Newlas has also developed a laser welding process expert database (NewPWED) that can support four basic types of Pin wire states and related composite terminal states.
The 2D camera system captures images using a coaxial camera to identify and obtain the coordinates of the Pin welding points. Combined with visual algorithms, it controls the deflection of the mirror to complete the recognition and guidance before welding.
X-pin motor solutions
For X-pin motor solutions, the exposed copper wires on the terminal connectors are relatively short, and the welding points are below the fixture. After turning the head, there is a significant height difference. In this case, the welding process is guided by combining 2D camera imaging recognition with 3D visual detection of the height difference of the workpiece.
Process Database
The laser welding process expert database, NewPWED, supports four basic flat wire states and their related complex terminal states.
System Advantages
High-efficiency production: The stator welding completion time for a 6-layer winding is <27S/P, and for an 8-layer winding, it is <35S/P;
High-quality welding: High-precision and high-speed mirror welding head + high-quality visual recognition + high adaptability welding process;
Expert database: Can intelligently match terminal states with welding processes, providing terminal welding quality and pass rates;
Integrated control: Independently designed and developed embedded system, achieving direct connection and communication between the visual system and the mirror system, with high matching performance;
Butler service: 7*24-hour service response, experienced service engineers, fast maintenance (core components proprietary), customizable function development.
Newlas’ one-stop laser welding solution for flat wire motors not only detects, identifies, and analyzes the assembly state of terminals but also monitors the welding state of pin wire terminals in real-time, intelligently adjusting output parameters. Simultaneously, it develops a laser welding process expert database to match various assembly states of the welded headers, calling the corresponding welding process according to requirements, to achieve intelligent high-quality and efficient welding production of flat wire motors.
Author：Mac
mengxiaojun@newlas.com
System Advantages
High-efficiency production: The stator welding completion time for a 6-layer winding is <27S/P, and for an 8-layer winding, it is <35S/P;
High-quality welding: High-precision and high-speed mirror welding head + high-quality visual recognition + high adaptability welding process;
Expert database: Can intelligently match terminal states with welding processes, providing terminal welding quality and pass rates;
Integrated control: Independently designed and developed embedded system, achieving direct connection and communication between the visual system and the mirror system, with high matching performance;
Butler service: 7*24-hour service response, experienced service engineers, fast maintenance (core components proprietary), customizable function development.
Newlas’ one-stop laser welding solution for flat wire motors not only detects, identifies, and analyzes the assembly state of terminals but also monitors the welding state of pin wire terminals in real-time, intelligently adjusting output parameters. Simultaneously, it develops a laser welding process expert database to match various assembly states of the welded headers, calling the corresponding welding process according to requirements, to achieve intelligent high-quality and efficient welding production of flat wire motors.
Author：Mac
mengxiaojun@newlas.com
