As the demand for high-efficiency, high-precision motors continues to rise across industries like new energy vehicles, rail transit, and industrial automation, traditional stator assembly methods are reaching their limits. The segmented stator laser welding system emerges as a game-changing solution—combining the structural flexibility of modular design with the precision and speed of laser welding.
This advanced system is specifically designed for the high-quality welding of segmented stator modules used in large industrial motors, electric vehicle (EV) traction motors, and specialty motors. By streamlining the stator assembly process, it addresses the core challenges of traditional methods—misalignment, heat distortion, and inconsistent joint quality—while opening the door to scalable, flexible production.
System Overview
The segmented stator laser welding machine adopts a single-station layout with manual loading and unloading, striking a balance between simplicity, safety, and adaptability. Powered by Han’s Laser precision control software, the system ensures intuitive operation, quick learning curves, and low operator training costs. Thanks to its modular mechanical and software design, it offers strong compatibility with various product sizes and configurations, making it ideal for both R&D labs and early-stage production environments.
Key Advantages
1.High Compatibility for Modular Production
The system’s modular design allows for easy fixture swaps and parameter adjustments, enabling seamless adaptation to different stator segment shapes and dimensions. Whether you’re switching between motor sizes or working on prototype development, this welding station adjusts quickly without sacrificing precision.
2.Enhanced Operational Safety
The machine separates the loading zone from the welding zone using a pneumatic safety door system. Operators load parts from outside the enclosure while laser welding occurs inside the shielded chamber—eliminating the risk of laser exposure. This clear zoning ensures compliance with strict workplace safety regulations without compromising workflow.
3.Compact & Serviceable Design
Its compact footprint is optimized for both lab and industrial use. Every module is easily accessible, making routine maintenance fast and cost-effective. The straightforward layout also allows for rapid integration into existing production lines or pilot runs.
4.Precision Welding with Laser Accuracy
Using finely tuned laser parameters and alignment systems, the machine delivers clean, reliable welds on stator segments with minimal heat-affected zones. This improves overall motor durability, magnetic performance, and operational stability—critical factors for high-efficiency motors in EVs and rail systems.
Application Areas
- New Energy Vehicles (EVs): Traction motor stators require highly repeatable, precision welding to meet performance and longevity standards.
- Rail Transit Motors: Modular design facilitates easier maintenance and assembly, while laser welding ensures vibration resistance in high-speed applications.
- Industrial Automation & Equipment: Stator modules for robotics and industrial drives benefit from flexible system configurations and consistent weld strength.
- Specialty Motors: Custom stators for aerospace or defense applications require the fine control and safety features that this system delivers.
Conclusion
The segmented stator laser welder is not a one-size-fits-all tool—it’s a purpose-built partner in your journey toward smarter, safer, and more adaptable motor production. From simplified single-station operation to modular compatibility and uncompromising safety features, every design detail is focused on solving real-world manufacturing pain points. As electric and intelligent mobility continues to advance, this system helps you stay ahead by making precision manufacturing more accessible and reliable.
Interested in learning more or seeing a demo? Contact Han’s Laser to find the right solution for your motor production needs.