Introduction

The segmented stator, as the core component of motors, directly determines overall performance. Widely used in permanent magnet synchronous motors and high-efficiency industrial motors, its assembly requires precise press-fitting of laminated segments and hermetic welding. Traditional manual or semi-automated methods often result in low throughput, inconsistent quality, and unstable welds—challenges that no longer meet the demands of modern motor manufacturing.

Han’s Laser developed the Segmented Automated Stator Assembly and Laser Welding System to overcome these bottlenecks. By integrating full automation, flexible positioning, and intelligent quality control, the system helps the motor industry transition toward high-end, reliable, and scalable manufacturing.

System Overview

This system adopts a modular design that organically integrates automatic press-fitting, laser welding, and automated ejection into a single workstation. The compact footprint allows seamless production line integration while simplifying long-term maintenance.

With interchangeable fixtures and parameter adjustments, the system easily accommodates different stator sizes, maximizing adaptability and ROI. Independent loading and welding stations enhance operational safety and ensure smooth workflows.

Through high-definition monitoring and video data capture, the laser welding machine provides complete process visualization—from loading and positioning to press-fitting, welding, and unloading. Every operation is traceable, supporting rigorous quality management and process optimization.

Key Advantages of Han’s Laser Solution

• Fully Integrated Automation: Greatly reduces manual intervention, improving efficiency and consistency across production.
• Safety by Design: Independent loading and welding zones separated by pneumatic doors prevent exposure to laser hazards.
• Flexibility and Compatibility: Rapid fixture replacement and parameter switching allow compatibility with diverse stator types.
• Modular Optimization: Simplifies operations, ensures easier upgrades, and supports cost reduction and efficiency gains.

Application Prospects

• New Energy Vehicles: Enables high-quality, high-sealing stator production for high-power-density permanent magnet synchronous motors, supporting powertrain advancements.
• Industrial Servo Motors: Provides reliable manufacturing for high-efficiency, long-lifespan stators, enhancing automation systems.
• Small Appliances, Aerospace, and Specialty Motors: Meets growing demand for micro and high-reliability stators, driving innovation in brushless DC and specialized motors.

Conclusion

The Han’s Laser Segmented Automated Stator Assembly and Laser Welding System redefines motor manufacturing by combining precision engineering, high efficiency, and intelligent process control. With its advanced automation and integration, Han’s Laser provides manufacturers with a cutting-edge solution to meet the evolving challenges of motor production.

Contact Han’s Laser today to explore how our solutions can help you achieve superior efficiency, reliability, and competitiveness in motor manufacturing.