PEM Researches Optimization of E-Motor Production through Vacuum Welding

Graphic showing laser beam, hairpin stator, and vacuum laser welding system Copyright: © PEM RWTH Aachen University

Together with the mechanical engineering company "LaVa-X", the Chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University is working on the optimization of the quality, costs, and time in the production of electric motors. The "ALIVE" project aims to research adaptive welding processes that take place in a vacuum during the production of the hairpin stator as a performance-determining component of current electric motors.

Partial lack of process understanding and too much scrap

In the development of modern motor topologies, hairpin stator technology has become established due to high feasible copper fill factors. At the same time, the corresponding processes for manufacturing the hairpin windings still represent a key challenge. The potential productivity of these technologies and the achievable quality level of hairpin stators cannot be realized at present due to the novelty of the process chain, the partial lack of process understanding, and high production scrap.

Challenge posed by quality-determining interactions

In the hairpin stator process chain, contacting of the hairpin ends by the laser welding process is a decisive section because it is subject to numerous process- and quality-influencing interactions from upstream process steps. The irreversible laser welding process is therefore a crucial bottleneck with regard to overall equipment effectiveness and cycle time in series production of hairpin technology.

Design of an adaptively controllable vacuum laser welding system

However, laser welding in a vacuum has a number of advantages, since the reduction in working pressure greatly increases process stability and high welding depths can be achieved. In the two-year "ALIVE" project, an adaptively controllable vacuum laser welding system for the hairpin contacting process is therefore to be set up by means of intelligent data utilization.

Further information is provided in this press release.



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The project

  • "ALIVE": Adaptive laser beam welding in vacuum of hairpin stators

Research objectives

  • Development of a vacuum laser welding process and system design for the hairpin stator process
  • Integration of adaptive control of the welding process and quality monitoring by using machine-learning algorithms

Research and project partners

PEM of RWTH Aachen University
LaVa-X GmbH
Visioning GmbH & Co. KG


  • 06/01/2023 through 05/01/2025

Project management

AiF Projekt GmbH

Funding code

  • KK5057505KT2


Federal Ministry for Economic Affairs and Climate Action (BMWK)