New Labs Create and Optimize Laser Welding for Electric Motors and Batteries

April 07, 2020 by Paul Shepard

Comau has created highly specialized laser laboratories to support companies as they develop, implement and optimize the laser processes involved in constructing and assembling electric motors and batteries. With two labs in Grugliasco (Turin) – one specialized in batteries and the other dedicated to electric motors, together with additional labs in Shanghai and Detroit, Comau has reinforced its 360° e-value chain by offering a wide range of laser processes for various industrial sectors such as automotive, aerospace, general industry, energy, oil and gas.

Comau aims to increase the efficiency, speed and value of production, thus enabling companies to offer highly competitive operational solutions for electrification sectors. As such, its specialized laser laboratories are equipped with Comau NJ-220 robots, which are capable of working simultaneously and on different types of applications and powered by the innovative LHYTE (Laser Hybrid Technology) system, developed by Comau in partnership with Prima Electro.

LHYTE is suitable for many different applications thanks to a patented solution which makes it possible to automatically alternate between fiber and diode lasers to ensure optimal high-precision joining, which is vital in the assembly of an e-battery or e-motor. LHYTE can also handle the complexity of working with different melting temperatures of materials such as copper and aluminum while guaranteeing a strong joint seal with a low level of electrical resistance.

“We can create any type of battery pack for any power level and are able to assemble the entire electrical battery, from the welding of individual cells which make up a module, to the stacking of the various modules contained in a battery pack, right through to the laser welding of the entire case,” explained Giovanni Di Stefano, Chief Technology Officer – Electrification, at Comau. “We are also developing a similar solution for hairpin motor laser welding at our newest lab.”

Comau’s laser laboratories can be configured, equipped and adapted to suit the process required and the type of product to be manufactured. In addition to accommodating a range of applications, Comau also develops and optimizes every phase of the laser welding process, from the prototype phase to the production of pre-series, when requested by the client.

Projects are supported by a dedicated group of engineers who develop or identify the best welding solution for each customer, with services ranging from feasibility studies right through to process optimization.