Innovative application of IDP-8210 high-precision resistance spot welder in the field of electric motors and rotors

Precision welding solutions based on high-frequency control and servo drive technology

I. Core advantages and technological innovations of IDP-8210 resistance spot welder

High-frequency inversion and multi-modal control

Adopting 1-5kHz high-frequency inversion technology, combined with 6 control modes (constant peak current, constant secondary current, constant voltage, constant power, constant pulse width, advanced hybrid control and other 6 major welding control modes), microsecond current response accuracy is achieved. This technology breaks through the limitations of traditional welding equipment in dynamic adjustment, and is particularly suitable for micron-level welding scenarios such as enameled wire and thin metal sheets.

Innovation of pressure control driven by servo motor

Multi-stage welding pressure adjustment (0.1N level accuracy) and welding head reset distance control are achieved through servo motors, which reduces the impact force by 80% compared with the cylinder drive solution. This feature can avoid material deformation during electric motor carbon brush welding and ensure the dynamic balance accuracy of the rotor after welding.

Full-process quality traceability system

The equipment has a built-in 8-inch touch screen that displays 8 waveform curves such as current, voltage, and power in real time, and stores 5 million welding data (including pressure and displacement parameters), and supports USB flash drive export to achieve full life cycle quality traceability.

II. Typical application scenarios in electric motor and rotor manufacturing

Brushed motor rotor commutator welding

For the heterogeneous material connection between copper commutator and enameled wire, IDP-8210 can accurately control the heat input through a hybrid control mode (current + power dual parameter closed loop) to avoid carbonization of the enameled wire insulation layer. Actual tests show that the welding yield rate can reach 99.3%, an increase of 15% over traditional equipment.

Micro motor carbon brush assembly welding

The 5kHz high-frequency mode is used with the slow rise/slow fall function to effectively suppress the welding spatter of the carbon brush silver contact. The servo pressure system realizes three-stage crimping (pre-pressing-welding-pressure holding) within a 0.5mm stroke to ensure that the bonding strength between the carbon brush and the reed reaches 20N/mm².

New energy vehicle drive motor welding

In the flat wire motor stator welding, the equipment supports multi-pulse cyclic discharge (up to 8 segments), and automatically compensates for the contact resistance change caused by copper bar oxidation through the real-time power monitoring function to ensure the consistency of the penetration depth of each weld.

III. Technology extension and industry value

The displacement penetration interruption function of IDP-8210 can detect the penetration depth of the weld in real time, and achieve 0.02mm control accuracy in the stack welding of silicon steel sheets for new energy motors. The equipment has been successfully applied to the rotor welding production line of Tesla suppliers, with an annual production capacity of more than 2 million pieces per unit and a 22% reduction in comprehensive energy consumption.