July 4, 2022. Vitesco Technology, the world's leading supplier of powertrain technology and sustainable mobility, is using an innovative laser system provided by its long-term production partner TRUMPF. With the use of new green laser equipment in copper welding, Vitesco Technology is one of the earliest suppliers to develop and promote green energy-saving solutions. Compared with current standard infrared laser system welding, the application of green laser can reduce energy consumption by up to 20%, thereby reducing carbon dioxide emissions produced by each laser welding joint. At the same time, the green laser system causes almost no copper spatter during the welding process, which means the production process is more efficient and more in line with 's sustainable development strategy .
Laser expert TRUMPF has developed this new green laser system for industrial production for the first time, which operates in the visible light spectrum with a wavelength of 515 nanometers. Compared with today's infrared laser welding technology with a wavelength of about 1,030 nanometers, the welding process using green laser is more energy-saving and controllable.
"Our sustainable manufacturing results in low CO2 emissions and very reliable processes. For car manufacturers, promoting sustainable development with high quality is of strategic importance and is a very competitive advantage. This is what we use The importance of green laser systems," said Thomas Stierle, member of the executive board of Vitesco Technologies.
Sustainable and innovative manufacturing technology: green laser
Copper welding is a very complex process. Today's electrification products require an ever-increasing number of copper soldered joints. So far, copper has been used in infrared laser systems (IR lasers). However, this process is difficult to control because the copper reflects almost all of the laser radiation before the soldering heats up suddenly. Special measures are required to protect the electronic system from copper splashes that may occur during the process. Due to high reflection and low energy absorption, the use of infrared lasers requires a large amount of energy consumption, which is contrary to the concept of sustainable development compared with green lasers.
"In terms of copper welding efficiency, green lasers are far better than infrared lasers. Rainer Pühl, director of operations of the New Energy Technology Division, added. "Green lasers not only consume less power, but also maintain a stable and repeatable process. to precisely control the penetration depth of copper. Based on these characteristics, green laser systems are currently becoming the standard technology of choice for enterprises.
“For us, copper welding is a frequently used and challenging task,” said Rodrigo Peres, Head of Battery Product Line at Vitesco Technologies. “We developed the new green laser over three years in collaboration with TRUMPF. system. The green laser system with a power of 2 kilowatts is currently used in the series production of highly integrated and complex battery management electronics for the BMW Group. "
" Green lasers have great potential for use in many electrified products. In addition to electronic products, it is also suitable for motors. With 138 welding points per motor, we can use welding processes on highly efficient stators," adds Pühl. One of the technical advantages of green lasers is that even particularly complex welds can be performed with a high-level, reliable process "Starting from manufacturing, green lasers are undoubtedly a key investment in the future of sustainable mobility," says Pühl.
