Development of a Quality Monitoring System for an Adaptive Vacuum Laser Welding Process for Hairpin Stators

Abstract

The production of hairpin stators for electric traction drives depends critically on laser welding, a process that defines overall quality due to its sensitivity to upstream process interdependencies. Laser welding in vacuum offers significant benefits for hairpin welding, including reduced porosity and enhanced weld penetration depth, leading to superior electrical conductivity and mechanical stability. This paper details the development of a quality monitoring system for an adaptive vacuum laser welding process, designed to improve the reliability and efficiency of hairpin stator manufacturing. The quality monitoring system follows VDI 2206 guidelines for mechatronic design and integrates vision systems for pre- and post-process monitoring, leveraging advanced deep learning for feature extraction from welding situations and outcomes. Supported by software and databases, it enables real-time adaptive control of welding parameters to optimize quality, cost, and time. The exact location of the defect for subsequent repair welding is also examined to enable an additional feedback loop. This comprehensive approach tackles production bottlenecks, ensures consistent high-quality welds under varying conditions.

Authors 6

1. Achim Kampker Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

2. Henrik Born Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

3. Michael Nankemann Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

4. Yazan Bajah Aachen Chair of Production Engineering of E-Mobility Components (PEM)

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University,Chair of Production Engineering of E-Mobility Components,Aachen,Germany

5. Benjamin Gerhards
   Affiliation as printed

   Lava-X GmbH,Herzogenrath,Germany

6. Stefan Rahmann
   Affiliation as printed

   Visioning GmbH & Co. KG,München,Germany