Xingte's Integrated Circular Splicing Laser Welding Solution Breaks Mass Production Bottlenecks of Frameless Torque Moto
2026/08/11
Frameless torque motors serve as the core direct-drive "hearts" for high-end sectors including humanoid robot joints, airborne aviation gimbals, precision medical devices, and new energy intelligent actuators.
Different from conventional motors, frameless torque motors eliminate housings, bearings and bases, retaining only stators and rotors that can be embedded directly into complete equipment systems. They feature zero backlash during deceleration, high torque density and ultra-sensitive dynamic response, making them an indispensable rigid demand for sophisticated high-end machinery.
To further improve slot fill factor, reduce copper loss and boost power density, the whole industry has shifted to segmented stator circular splicing technology, following the technical route: independent single-tooth winding → precision tenon splicing → laser welding fixation. The splicing and welding precision directly determines the noise level, torque stability, service life and mass production yield of frameless torque motors, which has long been a core bottleneck restricting large-scale manufacturing of high-end products.
Traditional one-piece full-circle stators suffer low slot fill factor and overly long end copper wires that generate heavy power loss, failing to meet strict standards of high power, compact size and low heat emission required by premium equipment.
The mainstream segmented independent winding plus circular splicing welding scheme effectively solves the above pain points:
- Independent winding on single teeth greatly raises the slot fill factor and cuts copper loss significantly.
- Greatly shortened end wires deliver more compact motor structures and higher power density.
- Precision tenon splicing guarantees uniform stator roundness and consistent air gaps.
- Integrated laser welding prevents stator separation, operational shaking and torque ripple.
Simply put, the precision and stability of splicing and welding processes define both the performance tier and mass production capacity of frameless torque motors.
Frameless stators are laminated from 0.2–0.5mm ultra-thin silicon steel sheets, featuring thin walls, high susceptibility to deformation, heat sensitivity and ultra-high precision requirements. Conventional argon arc welding and separate ordinary laser equipment cannot satisfy high-volume premium manufacturing, bringing five long-standing drawbacks:
- Insufficient positioning accuracy leads to shaking and abnormal noise
Traditional machines have limited positioning precision. Deviations cause out-of-tolerance stator roundness and unbalanced air gaps between stators and rotors, resulting in vibration, abnormal noise and excessive torque fluctuation during high-speed operation. Offset welds also trigger cold joints and missing welds, bringing risks of stator separation after long-term operation.
- Uncontrollable heat input causes iron core deformation and insulation damage
Silicon steel conducts heat rapidly while enameled windings have limited heat resistance. Traditional welding creates wide heat-affected zones that easily warp iron cores and burn winding insulation, leading to inter-turn short circuits. Weld seams often contain pores and cracks, dragging the overall industry yield below 85% with high rework and scrap costs.
3.Fragmented procedures result in inconsistent mass production
Traditional production lines separate circular splicing, welding and water cooling into individual stations. Multiple transfers introduce secondary positioning errors, and extensive manual intervention creates batch-to-batch discrepancies. Uninterrupted 24-hour automated production cannot be realized, failing to match capacity expansion plans of leading manufacturers.
4.Cumbersome model changeover lacks flexible production capacity
Specifications of humanoid robot and aviation motors iterate rapidly, with frequent changes to stator outer diameters, segment counts and weld positions. Traditional fixtures require complicated disassembly and assembly, and parameters cannot be reused quickly. Single model changeover takes over 2 hours, causing severe capacity waste in small-batch, multi-variety production modes.
5.Absence of online quality inspection makes quality untraceable with delayed defect detection
Traditional production only relies on manual sampling of finished products. Critical indicators suchs as weld penetration and roundness lack real-time monitoring. Most defects are only discovered after full assembly, multiplying material waste and rework costs and rendering quality control ineffective.
As a national key specialized and innovative "Little Giant" enterprise, Xingte Technology has years of deep experience in motor manufacturing. We have developed dedicated laser welding machines for stator circular splicing to address all bottlenecks in frameless torque motor production.
This all-in-one equipment integrates circular splicing, laser welding, follow-up cooling and MES data traceability, delivering a one-stop precision manufacturing solution for high-end frameless motors.
- Ultra-precise positioning for fully controllable stator roundness
Equipped with high-precision servo drives and precision fixture positioning systems, the machine achieves ±0.005mm XY positioning accuracy and ±0.01mm repeated positioning accuracy. Precise circular calibration is completed before welding to eliminate splicing misalignment. The roundness of finished stators is stably controlled within 0.02–0.05mm, fundamentally eliminating motor vibration, noise and torque ripple to meet strict assembly and operation standards of premium motors.
- Low thermal-impact laser technology eliminates insulation damage and minimal deformation
Fiber pulsed laser energy zoning control is customized for welding 0.2–0.5mm thin silicon steel sheets. A built-in follow-up cooling module delivers directional heat dissipation during welding, shrinking the heat-affected zone by 60%. Iron core deformation is minimized, winding insulation remains fully intact, and welds are dense without pores or cracks to satisfy rigorous standards for high-dynamic, high-reliability applications.
- Fully integrated workflow eliminates transfer errors and boosts efficiency greatly
The machine integrates five automatic stations: feeding, precision tenon locking, synchronous laser welding, instant cooling and dimensional inspection. Robots handle all material transfer without manual operation, supporting one-click switch between full-automatic and semi-automatic modes. One single unit replaces three separate traditional machines, cutting production line footprint by 40% and raising production tact by 35%.
- Full-chain intelligent monitoring enables traceable quality control
A built-in industrial touch screen and reserved MES communication ports collect real-time data including laser power, welding trajectory, roundness and weld penetration. Audible and visual alarms trigger automatically for abnormalities, with defective products diverted separately. Manual sampling is no longer required, and the overall mass production yield stably exceeds 99%.
- Modular quick-change fixtures support flexible manufacturing for all product ranges
Standardized modular fixture bases cut single model changeover time to only 15 minutes. A built-in full-spec process parameter database allows one-click recall of process schemes for humanoid robot joints, aviation gimbals and new energy torque motors, covering stators with outer diameters from 30mm to 100mm. It perfectly fits flexible customized production with multiple varieties and small batches.
At present, this equipment has been mass supplied to leading domestic humanoid robot manufacturers, aviation component suppliers and top servo joint enterprises. It is widely adopted in high-end fields including large & small joints of humanoid robots, precision motors for airborne aviation stabilizers, collaborative industrial robot joints, galvanometer motors for laser radars, and precision medical actuators.
The core challenge in high-volume, high-end production of frameless torque motors lies not in winding or assembly, but in micron-level precise control and stable processes during circular splicing and welding.
Xingte’s integrated circular splicing laser welding machine completely resolves traditional industry bottlenecks with four core strengths: ultra-precise positioning, low-deformation laser processing, fully integrated intelligent manufacturing and flexible quick-change production. We provide high-precision, high-yield, traceable core process solutions for humanoid robotics, aerospace and high-end automation industrial chains, and effectively elevate the manufacturing level of domestic premium frameless torque motors.
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