MotorWeld-GH1000: Green Laser Welding for EV Motor Copper Hairpin Stators

The MotorWeld-GH1000 is a dedicated green laser welding system for EV motor copper hairpin stator manufacturing. Using a 1000W continuous-wave green laser (532nm), it achieves stable, spatter-free welds on bare copper hairpin ends — a process that infrared fiber lasers cannot reliably perform due to copper's near-zero IR absorption at room temperature.

Key Features

• 1000W green laser (532nm) — 5× higher absorption on copper vs. 1070nm IR laser
• Spatter-free welding: stable keyhole without the explosive vapor ejection common in IR copper welding
• Multi-pin simultaneous welding: galvo scanner welds 4–8 hairpin pairs per cycle
• Vision-guided alignment: automatic hairpin tip detection and focus compensation
• Weld depth control: closed-loop OCT (optical coherence tomography) monitoring
• Compact footprint: 1200×900mm, integrates into existing stator assembly lines

Technical Specifications

Applications

Flat wire (hairpin) motor stator welding for EV traction motors, hybrid vehicle motors, and high-efficiency industrial motors. Compatible with round wire end-turn welding and busbar-to-terminal connections.

Why Green Laser for Copper Hairpin?

Copper reflects over 95% of 1070nm infrared laser energy at room temperature. This causes unstable keyhole formation, excessive spatter, and inconsistent weld depth — leading to high rejection rates in hairpin motor production. The GH1000's 532nm green laser is absorbed at >40% efficiency by copper, enabling stable, repeatable welds with spatter levels below 0.1mg per joint and weld resistance consistently below 0.05mΩ.