The micro arc coil termination process requires wire to be wound onto the pin in a uniform fashion and density. Sophisticated closed loop power supplies are used to establish and maintain the arc under precisely controlled electrical conditions. The arc generates very high and concentrated energy density, which results in high local temperatures that can be used for welding. Pulse micro arc welding is a zero-contact process in which an electrical arc is struck between an electrode and target component. Multiple output pulsed arc welders are available that offer great automation layout flexibility and increase production line throughput. For example, it can be difficult for lasers to target the pins, while resistance welding is not practical due to electrode size, and soldering involves potentially hazardous fluxes. Other processes do not lend themselves as well for these applications. Pulse micro arc welding is a good choice for coil termination applications, especially as coils are getting smaller and smaller. Coils with multiple termination points can be welded at one automation station.
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