EV batteries, inverters and motors
EV batteries, inverters and motors
Evflow electron beam column
Evflow electron beam column
Evflow is an electron beam welding machine for electric vehicle powertrain production. Its primary application is stator welding, joining hairpin and X-pin windings, with the same machine also used for busbars, inverters and battery components.
Welding takes place in a vacuum, which removes oxidation and the reflectivity problems that make copper difficult to weld by laser. The result is a consistently strong joint with minimal porosity, very little spatter and substantially higher tensile strength than a comparable laser weld. The beam is deflected electromagnetically with no moving parts, so it moves faster than a mechanical laser mirror.
You can change the focal point of the electron beam dynamically and rapidly using electromagnetic focusing coils, allowing it to process very wide areas without moving the component or the weld head mechanically. That same control places the beam precisely, and meters its power accurately, on the tighter geometries of X-pin windings.
Evflow is an electron beam welding machine for electric vehicle powertrain production, with stator welding as its primary application. It joins hairpin and X-pin windings, and also welds busbars, inverters and battery components.
Because the weld is made in a vacuum, there is no oxidation and none of the reflectivity problems that make copper difficult to weld by laser. Joints show minimal porosity and very little spatter, and reach a substantially higher tensile strength than comparable laser welds. ETP copper and aluminium can both be used, and dissimilar joints such as copper to aluminium are achievable.
Electron beam welding is also significantly faster for this application, as the beam is deflected electromagnetically with no moving parts, allowing it to move faster than a mechanical laser mirror. At around 100ms per weld, a stator with 192 welds takes about 30 seconds, against about 70 seconds by laser. Preparation is reduced too, with no hairpin trimming required and a shorter insulation cut-back distance.
Evflow is used primarily in the electric vehicle industry, welding motor stators, busbars, inverters and battery components. The same electron beam welding technology also serves CVE’s other industries, from aerospace to nuclear power generation.
