As NEV e-motor technologies such as Hair-Pin, X-Pin, and Mini-Pin continue to evolve, the demands on welding quality have become increasingly stringent. To address key challenges—such as difficulty in controlling weld penetration depth in pin wire welding, significant keyhole fluctuations, and complex weld spot segmentation—we have partnered with Newlas to launch a real-time quality inspection solution for laser welding of hairpin windings based on Optical Coherence Tomography (OCT).

This solution coaxially integrates the OCT inspection beam path with the welding beam path, enabling real-time detection of the keyhole bottom depth during the welding process. It accurately captures penetration depth and weld fusion area data for each weld spot. By innovatively incorporating an EPS device for full-field coaxial alignment of the inspection and welding beams, and developing algorithms for positioning, segmentation, rotation, filtering, slicing, and fitting, we effectively overcome technical challenges such as keyhole tail fluctuation and beam coaxiality differences. The solution is compatible with complex processes including skip welding and multiple laser firings, which empowers customers to achieve their goal of zero-defect welding.