Repair of Defective Contact Points in Hairpin Stator Production Using Laser Welding

In the hairpin stator production chain, the contacting process acts as a so-called quality gate. This is where the base for the electrical functionality of the stator is generated. Faulty welding leads to product rejects, which results in high costs due to the advanced stage of value creation. Due to the large number of welding points in a hairpin stator and the complex boundary conditions and process control during laser contacting, a significant proportion of the reject rates in production can be attributed to this process step. This work therefore aims to investigate which general conditions can result in which defects at the contact point. And furthermore, how possible strategies for repair welding these defects can be designed to reduce the reject rate and increase the sustainability of the production process.