High-power laser welding multi-stage protection and dust extraction integrated device and control method
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHENZHEN QIONGJI LASER EQUIPMENT CO LTD
- Filing Date
- 2025-12-31
- Publication Date
- 2026-06-26
Smart Images
Figure CN122274407A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of laser welding technology, specifically a high-power laser welding multi-level protection and dust extraction integrated device and control method. Background Technology
[0002] For welding high-reflectivity materials such as stainless steel and aluminum alloys, as well as thick plates, laser welding is typically used. These materials are often 3-50mm thick, requiring high-power laser welding for effective processing. During the welding process, the resulting fumes and spatter significantly impact weld quality and stability, leading to inconsistent weld results even with the same parameters.
[0003] Current laser welding equipment generally suffers from the following problems: 1. Insufficient gas protection: It uses a single-layer gas curtain, which cannot cover the large molten pool (width > 5mm) of high-power welding, resulting in a spatter density > 200 spatters / cm², and high consumption of inert gas (Ar gas > 30L / min); 2. Low dust extraction efficiency: Although a dust extraction system is provided, it operates at a fixed wind speed, meaning the wind speed often remains constant throughout the welding process. This fixed-speed dust extraction system cannot match the dynamic welding trajectory, resulting in a dust capture rate < 70%, and residual particles leading to a weld porosity > 1.5%; 3. Poor heat-affected zone control: It lacks real-time thermal field monitoring, and heat accumulation during thick plate welding causes deformation, with warping > 0.5mm / m; 4. High maintenance costs: Frequent filter clogging, replacement cycle < 40 hours, and equipment downtime rate > 15%. Summary of the Invention
[0004] To address the aforementioned technical problems, this invention provides an integrated device and control method for multi-level protection and dust extraction in high-power laser welding.
[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A high-power laser welding multi-level protection and dust extraction integrated device includes a housing. A nozzle, an air inlet, and a dust extraction pipe are installed at the lower part of the housing. The housing has a main protection channel and a dust extraction channel communicating with the nozzle. One end of the dust extraction channel is connected to the dust extraction pipe, and the other end of the dust extraction channel is connected to the inside of the suction nozzle. A dust extraction module communicating with the channel is installed inside the housing. A temperature sensor, a dust measurement sensor, and a vibration sensor are installed on the housing. A radar detector is installed on the upper part of the housing. A rear protection channel is formed between the nozzle and the side wall of the housing. The air inlet is connected to the gap channel. The diameter of the dust extraction channel is smaller than the inner diameter of the suction nozzle, so that the inside of the suction nozzle and the dust extraction channel form a Venturi suction structure. A fly-intercepting layer is provided on the housing above the dust extraction pipe. The dust extraction pipe is rotatably connected to the housing.
[0006] The lower part of the housing is equipped with an electrostatic adsorption module, and the upper part of the suction nozzle passes through the electrostatic adsorption module and is connected to the housing.
[0007] The electrostatic adsorption module is a honeycomb electrode plate.
[0008] The interceptor layer includes a cavity with an internal arc-shaped surface, and the cavity sidewalls are provided with vents.
[0009] The dust extraction module includes a miniature vortex fan, which is connected to the dust extraction channel.
[0010] The housing contains a filter assembly located above the nozzle, which includes a sintered metal filter element and a ceramic fiber membrane.
[0011] A control method for a high-power laser welding multi-level protection and dust extraction integrated device includes the following steps: Argon gas is introduced through the main protection channel, blown out from the nozzle, and covers the core area of the molten pool. Tangential vortex compressed air is introduced from the spatter interception layer to capture spatter particles, and helium gas is introduced from the air inlet and blown toward the molten pool to prolong the cooling time of the molten pool and suppress the formation of oxide layer. By drawing or blowing air into the dust extraction port, air is expelled from inside the dust extraction channel, creating a local negative pressure environment in the area above the nozzle. This is used to capture the smoke and dust above the molten pool in real time, and to capture charged particles through the electrostatic adsorption module. Based on real-time data detected by temperature sensors, dust measurement sensors, and vibration sensors, the ventilation volume of gas at different locations is adjusted. By scanning the welding path with radar, the trajectory of smoke and dust diffusion is predicted, and the angle of the dust extraction pipe is dynamically adjusted.
[0012] When the temperature sensor detects that the temperature of the molten pool is higher than the temperature threshold, nitrogen gas is introduced from the gas inlet for pre-cooling. When the dust measurement sensor detects that the dust level is higher than the dust threshold, the electrostatic adsorption module is activated. The vibration sensor detects the impact force of the splash and adjusts the ventilation volume of the tangential vortex compressed air in the splash interception layer.
[0013] The argon gas introduced into the main protective layer has a purity of 99.999%, a flow rate of 25-35 L / min, and a coverage width of ≥8 mm covering the core area of the molten pool; the tangential vortex compressed air of the spatter interception layer has a pressure of 0.6-1.0 MPa, an angular velocity of >3000 rad / s, and captures spatter particles with a diameter >10 μm.
[0014] The present invention has the following beneficial technical effects: Multi-stage gas protection: Traditional single-stage gas protection is difficult to effectively prevent contamination from plasma and metal vapor. This invention adopts multi-stage gas protection, which can better protect the laser focusing lens and weld area.
[0015] Dynamic fume extraction: Traditional fixed fume extraction devices are difficult to effectively remove fumes generated during welding. This invention uses a dynamic fume extraction device that can dynamically adjust according to the concentration and location of the fumes to ensure effective removal of fumes.
[0016] Real-time monitoring: Traditional welding process monitoring mainly relies on human experience. This invention uses multiple sensors and cameras for real-time monitoring, which can promptly detect and resolve problems in the welding process and improve welding quality.
[0017] Integration: Multi-stage gas protection, dynamic fume extraction, and real-time monitoring are integrated into one device, enabling comprehensive control and optimization of the welding process. Attached Figure Description
[0018] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a schematic diagram of the assembled three-dimensional structure of the present invention; Figure 3 This is a partial cross-sectional structural diagram of the present invention. Detailed Implementation
[0019] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0020] In the description of this invention, it should be understood that if terms such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.
[0022] like Figure 1-3 As shown, a high-power laser welding multi-level protection and dust extraction integrated device includes a housing 1. A nozzle 2, an air inlet 3, and a dust extraction pipe 4 are installed at the lower part of the housing 1. The housing 1 has a main protection channel 5 and a dust extraction channel 6 that communicate with the nozzle 2. One end of the dust extraction channel 6 is connected to the dust extraction pipe 4, and the other end of the dust extraction channel 6 is connected to the inside of the suction nozzle 2. The housing 1 has a dust extraction module that communicates with the channel. A temperature sensor, a dust measurement sensor, and a vibration sensor 7 are installed on the housing 1. A radar detector 8 is installed on the upper part of the housing 1. A rear protection channel 9 is formed between the nozzle 2 and the side wall of the housing 1. The air inlet 3 is connected to the gap channel. The diameter of the dust extraction channel 6 is smaller than the inner diameter of the suction nozzle 2, so that the inside of the suction nozzle and the dust extraction channel form a Venturi suction structure. The housing 1 has a fly interception layer 10 located above the dust extraction pipe. The dust extraction pipe is rotatably connected to the housing. The vibration sensor is a piezoelectric vibration sensor used to detect the splash impact force.
[0023] The nozzle body is made of Inconel 718 alloy and the surface is coated with a 200μm Al2O3-ZrO2 gradient coating, which can withstand temperatures >1800℃. The diameter of the dust extraction channel is smaller than the inner diameter of the nozzle, creating a Venturi suction structure between the nozzle and the dust extraction channel. This structure can be achieved by setting a constriction section at the inlet of the dust extraction channel. When the airflow passes through this constriction section, the flow velocity increases, thereby creating a local negative pressure inside the nozzle.
[0024] The housing 1 is provided with a fly interception layer 10 located above the dust extraction pipe 4. This fly interception layer can be a simple metal mesh used to block larger flying particles.
[0025] The dust extraction pipe is rotatably connected to the housing. This rotatable structure can be a simple rotary joint that allows the dust extraction pipe to rotate about its axis, thereby adjusting the direction of dust extraction.
[0026] The high-power laser welding multi-level protection and dust extraction integrated device provided in this embodiment achieves comprehensive gas coverage of the large molten pool in high-power welding by setting up a main protection channel and a rear protection channel, effectively reducing spatter density and optimizing inert gas consumption. Simultaneously, the use of a Venturi suction structure and a rotatable dust extraction pipe significantly improves the efficiency of fume capture, reducing weld porosity. Furthermore, the integration of temperature sensors, fume measurement sensors, vibration sensors, and radar detectors provides data support for real-time monitoring and control of the welding process, helping to optimize heat-affected zone control, reduce workpiece deformation, and extend equipment maintenance cycles.
[0027] In some embodiments described above, a multi-level protection and dust extraction integrated device for high-power laser welding is proposed. This device, through a main protection channel, a dust extraction channel, and a spatter interception layer, achieves protection of the molten pool and preliminary capture of fumes and spatter particles. However, in actual high-power laser welding processes, a large number of tiny fumes and dust particles are generated, some of which may be charged. These fine charged particles are difficult to capture efficiently through simple airflow suction or mechanical interception, and easily escape into the environment, affecting welding quality and the health of operators.
[0028] In this regard, this application further proposes that an electrostatic adsorption module is installed in the lower part of the housing, and the upper part of the suction nozzle passes through the electrostatic adsorption module and is connected to the housing.
[0029] An electrostatic adsorption module is a device that uses electrostatic principles to capture particulate matter in the air. Its working principle typically involves charging airborne particles with a high-voltage electric field, then using the electric field force to attract the charged particles to the collecting electrode. This module can efficiently capture extremely small particles, including submicron-sized dust and charged particles that are difficult to remove completely by conventional airflow suction. Its implementation can include, but is not limited to, a structure with a high-voltage discharge electrode and a grounded collecting electrode. By applying high voltage between the electrodes, a corona discharge region is formed, charging the flowing dust particles, which are then collected under the influence of the electric field force. The electrostatic adsorption module is installed inside the lower part of the housing. This location allows the module to be closer to the source of dust and splash particles, namely the molten pool area. Integrating it inside the housing effectively utilizes the overall space of the device and ensures its effective role in the protective gas and dust extraction airflow paths. The upper part of the suction nozzle passes through the electrostatic adsorption module and connects to the housing, meaning that during the dust extraction process, the airflow path passes through the electrostatic adsorption module. This structural design ensures that the smoke and dust are fully exposed to the electric field generated by the electrostatic adsorption module before entering the dust extraction channel, thereby effectively capturing the charged particles in the smoke and dust and improving the overall smoke and dust purification efficiency.
[0030] By incorporating an electrostatic adsorption module 12 inside the lower part of the housing 1, and allowing the upper part of the suction nozzle 2 to pass through this module 12, this application effectively solves the problem of inefficiently capturing fine charged dust particles during high-power laser welding. When the welding fumes are drawn in by the suction nozzle, these fumes pass through the electrostatic adsorption module. The electrostatic adsorption module utilizes its generated electric field to charge and adsorb the particles in the fumes, thereby further capturing extremely small or charged particles on top of mechanical dust extraction. This integrated design significantly improves the dust purification efficiency, reduces the emission of harmful particles, provides a cleaner working environment for operators, and helps maintain the cleanliness of the molten pool area, thereby indirectly improving welding quality.
[0031] In some of the embodiments described above in this application, a technical solution for capturing charged particles by an electrostatic adsorption module is proposed. However, in the actual process of capturing high-power laser welding fumes, traditional electrostatic adsorption modules may have problems such as insufficient adsorption efficiency, large gas flow resistance, or limited effective adsorption area, which affect the effective removal of fine dust particles.
[0032] In this regard, this application further proposes that the aforementioned electrostatic adsorption module is a honeycomb electrode plate. A honeycomb electrode plate is an electrode plate with a porous, grid, or channel structure, typically composed of a large number of regularly arranged micropores or channels, resembling a honeycomb. This structural design significantly increases the surface area of the electrode plate, thereby providing more adsorption sites for charged particles. In the electrostatic adsorption module, a high-voltage electric field is applied to the honeycomb electrode plate, causing corona discharge on its surface. This charges the dust particles in the passing airflow, which are then adsorbed onto the electrode plate surface. Its multi-channel structure also helps reduce airflow resistance, ensuring dust extraction efficiency while improving the ability to capture fine particles.
[0033] By employing honeycomb electrode plates as electrostatic adsorption modules, the contact area between the electrode plates and dust particles is significantly increased, thereby greatly improving the collection efficiency of charged dust particles generated during high-power laser welding. The honeycomb structure not only provides abundant adsorption sites, but its multi-channel design also effectively reduces airflow resistance, ensuring smooth operation of the dust extraction channel and preventing a decrease in dust extraction efficiency due to excessive resistance. Furthermore, this structure helps to uniformly distribute the electric field, ensuring that dust particles are fully charged and effectively adsorbed as they pass through the module. This achieves more thorough removal of fine dust particles without affecting overall dust extraction performance, further enhancing the dust purification capability of the integrated device.
[0034] In some embodiments described above in this application, the high-power laser welding multi-level protection and dust extraction integrated device is equipped with a fly-by interception layer to capture spatter particles generated during the welding process. However, in practical applications, a simple fly-by interception layer may be insufficient to efficiently capture spatter particles of all sizes and velocities, especially in high-speed welding or complex working conditions. Some spatter particles may escape due to airflow disturbance or insufficient capture efficiency, affecting welding quality or equipment cleanliness.
[0035] In this regard, this application further proposes that the aforementioned interceptor layer includes a cavity with an internal arc-shaped surface, and the cavity sidewall is provided with an air vent.
[0036] Specifically, the internal surface of the cavity is curved, rather than flat or straight. This curved surface design effectively guides the airflow entering the cavity and the trajectory of splash particles. When the airflow carrying splash particles enters the curved cavity, the curved wall can cause the airflow to form vortices or change its direction, thereby using centrifugal force or inertial force to throw the splash particles against the cavity wall, increasing the probability of particles colliding with and being captured by the wall. The specific curvature and geometry of the curved surface can be optimized according to the expected airflow velocity, particle size distribution, and density of the splash particles. For example, it can be designed as a parabola, spiral, or simple arc to maximize the capture effect on different types of splash particles. At the same time, these vents are openings set on the side walls of the curved cavity to control the entry and exit of gas into the cavity. Through these vents, gas can be introduced or discharged, thereby forming a specific airflow pattern inside the cavity. For example, the vents can be designed as tangential jets, which can generate strong vortex airflow inside the cavity when gas (such as compressed air) enters the cavity through these tangential vents. This vortex airflow further enhances the capture capability of splash particles, pushing them against the cavity wall through centrifugal force and causing them to move along the wall before being collected or discharged. The number, size, shape, and angle of the vents relative to the cavity axis can all be precisely designed to optimize the airflow distribution and intensity, ensuring efficient capture of splash particles.
[0037] Through the above technical solution, the fly-by interceptor layer adopts an internal arc-shaped cavity design, combined with vents on the sidewalls of the cavity, which effectively solves the problem of insufficient capture efficiency in traditional fly-by interceptor layers. The arc-shaped cavity guides the airflow and spatter particles to form a stable vortex or a controlled trajectory, while the vents on the sidewalls precisely introduce tangential airflow, further enhancing the vortex effect and generating a powerful centrifugal force that efficiently throws and captures the spatter particles against the cavity wall. This design significantly improves the capture efficiency of spatter particles, reduces contamination of the welding area and damage to the equipment caused by spatter particles, thereby ensuring the stability and quality of the welding process and extending the service life of the equipment.
[0038] In some of the embodiments described above in this application, although a dust extraction module communicating with the dust extraction channel is provided inside the housing for dust capture, in practical applications, traditional dust extraction modules may have problems such as insufficient suction efficiency, large size, or high energy consumption, making it difficult to provide strong and stable suction in a limited space, thereby affecting the timely and effective removal of dust.
[0039] To address this, this application further proposes a dust extraction module including a miniature vortex fan with a power of 1.5kW and a noise level of <65dB, which is connected to the dust extraction channel. A miniature vortex fan is a micro-fluidic machine that utilizes the principle of vortex airflow to generate negative or positive pressure. It typically consists of one or more vortex impellers, which generate centrifugal force through high-speed rotation, drawing in gas and discharging it along the vortex path, thus forming a powerful airflow. In this embodiment, the miniature vortex fan, as the core component of the dust extraction module, primarily provides continuous and powerful suction power to the dust extraction channel to efficiently capture fumes and spatter particles generated during laser welding. This miniature vortex fan can be driven by a DC brushless motor, and its impeller design can be optimized into a multi-stage vortex structure to achieve higher pressure head and flow rate within a compact volume. To adapt to the laser welding environment, the fan material can be a high-temperature resistant and corrosion-resistant alloy, and a vibration damping structure can be integrated to reduce vibration and noise. Its size and power should be selected based on the required suction volume and the overall space constraints of the device. The connection between the miniature vortex blower and the dust extraction duct is designed to ensure that the negative pressure generated by the miniature vortex blower can directly act on the dust extraction duct, thereby creating an effective suction airflow inside the nozzle to draw in smoke and particulate matter from the welding area. The connection can be made directly through flexible or rigid pipes, ensuring a tight seal at the connection point to prevent air leakage from affecting suction efficiency. For example, the blower's air inlet can be tightly connected to the inlet of the dust extraction duct using flange connections, threaded connections, or clamp connections. For ease of maintenance and replacement, the connection can be designed as a detachable structure.
[0040] The above technical solution specifically implements the dust extraction module as a miniature vortex fan. This device utilizes the characteristics of small size, high power, and high suction efficiency of the miniature vortex fan to provide strong and stable negative pressure within a limited housing space. After being connected to the dust extraction channel, the miniature vortex fan efficiently drives the airflow within the channel, enhancing the effect of the Venturi suction structure formed by the nozzle and the channel. This creates a stronger local negative pressure environment above the nozzle, achieving real-time and efficient capture of fumes above the molten pool. This not only solves the problems of insufficient suction efficiency, large size, or high energy consumption that may exist in traditional dust extraction modules, but also ensures that fumes and spatter particles can be quickly and effectively removed, significantly improving environmental protection and operational safety during high-power laser welding.
[0041] In this regard, this application further proposes that a filter assembly is provided inside the housing of the above-mentioned device and above the suction nozzle, the filter assembly including a metal sintered filter element and a ceramic fiber membrane.
[0042] This filtration unit is used for deep purification of gases extracted from the welding area. Its main function is to remove residual solid particles and harmful fumes from the gas, ensuring that the discharged gas meets higher cleanliness standards. This unit is typically designed with a removable or easily maintained structure for convenient regular cleaning or replacement.
[0043] Metal sintered filter elements are porous filter elements formed by sintering metal powders (such as stainless steel powder, bronze powder, etc.) at high temperatures. They are characterized by high mechanical strength, good corrosion resistance, and high-temperature resistance. By controlling the sintering process, the pore size distribution of the filter element can be precisely controlled, enabling it to effectively capture solid particles within a certain size range. In this application, metal sintered filter elements are typically used as pre-filters to remove larger fine particles from the gas, thereby reducing the load on subsequent fine filter elements and extending their service life.
[0044] Ceramic fiber membranes are membrane filtration elements made of ceramic fiber materials. These membranes possess excellent high-temperature resistance and chemical corrosion resistance, and can achieve extremely high filtration accuracy, effectively capturing submicron-sized ultrafine particles and aerosols. In laser welding fume treatment, ceramic fiber membranes can efficiently remove harmful substances such as metal oxide fumes and volatile organic compounds, making them a key component for achieving deep purification. Their microporous structure ensures high-efficiency filtration even at relatively low pressure drops.
[0045] Therefore, this application further proposes the control method, the specific steps of which include: Argon gas is introduced from the main protection channel, blown out from the nozzle, and covers the core area of the molten pool. Tangential vortex compressed air is introduced from the splash interception layer to capture splash particles; Helium gas is introduced through the inlet and blown toward the molten pool to prolong the cooling time of the molten pool and suppress the formation of the oxide layer; By drawing or blowing air into the dust extraction port, air is expelled from inside the dust extraction channel, creating a local negative pressure environment in the area above the nozzle. This is used to capture the smoke and dust above the molten pool in real time, and to capture charged particles through the electrostatic adsorption module. Based on real-time data detected by temperature sensors, dust measurement sensors, and vibration sensors, the ventilation volume of gas at different locations is adjusted. By scanning the welding path with radar, the trajectory of smoke and dust diffusion is predicted, and the angle of the dust extraction pipe is dynamically adjusted.
[0046] In the aforementioned control method, argon gas is introduced from the main protective channel and blown out through nozzles to cover the core area of the molten pool, aiming to provide inert gas protection for the molten pool. As an inert gas, argon effectively isolates the molten pool from contact with oxygen and nitrogen in the atmosphere, thereby inhibiting harmful reactions such as oxidation and nitriding, and ensuring the purity and mechanical properties of the weld. By precisely controlling the argon gas flow rate and the nozzle structure, it can be ensured that the argon gas flow can stably and uniformly cover the core area of the molten pool, forming an effective protective layer.
[0047] Simultaneously, tangential vortex compressed air is introduced from the spatter interception layer, its main function being to capture spatter particles generated during the welding process. During high-power laser welding, molten metal may be ejected in the form of spatter. By forming a tangential vortex airflow inside the spatter interception layer, centrifugal force and airflow entrainment can be used to effectively intercept and collect these spatter particles, preventing them from contaminating optical components, affecting welding quality, or dispersing into the environment. The arc-shaped cavity inside the spatter interception layer and the air vents on the side walls help to efficiently generate and maintain this vortex airflow.
[0048] Furthermore, introducing helium gas through the inlet and blowing it onto the molten pool aims to prolong the cooling time of the molten pool and further suppress oxide layer formation. Helium has a high thermal conductivity, and when it is blown onto the molten pool, it helps dissipate heat from the surrounding area, thereby slowing down the cooling rate of the molten pool. Appropriately extending the cooling time helps reduce solidification defects and improve the microstructure of the weld. As an inert gas, helium also provides additional protection for the molten pool, further reducing the risk of oxidation.
[0049] To capture smoke and dust above the molten pool and trap charged particles in real time, this method creates a localized negative pressure environment above the nozzle by drawing or blowing air into the dust extraction port, causing air to escape from the inside of the extraction channel. This negative pressure environment efficiently draws smoke and dust and fine particles generated above the molten pool into the extraction channel. The design of the extraction channel's diameter being smaller than the nozzle's inner diameter creates a Venturi suction structure, further enhancing suction efficiency. Based on this, an electrostatic adsorption module (e.g., a honeycomb electrode plate) is activated, capturing any charged particles that may be present in the smoke through electrostatic attraction, achieving deep purification of the smoke.
[0050] This method also incorporates an intelligent feedback control mechanism. Based on real-time data detected by temperature sensors, dust measurement sensors, and vibration sensors, the system can dynamically adjust the gas flow rate at different locations. For example, when the temperature sensor detects an abnormally high temperature in the molten pool, the flow rate of helium or argon can be adjusted to enhance cooling or protection; when the dust measurement sensor detects excessively high dust concentration, the workload of the dust extraction module can be increased; and when the vibration sensor detects excessive splash impact force, the flow rate of the tangential vortex compressed air in the splash interception layer can be adjusted to more effectively capture splashes. This adaptive adjustment capability ensures optimal protection and dust extraction performance under various operating conditions.
[0051] Finally, by scanning the welding path with radar, the system can predict the diffusion trajectory of the fumes and dynamically adjust the angle of the suction pipe accordingly. The complexity of the welding path may lead to changes in the direction of fume diffusion. The radar detector can acquire spatial information of the welding area in real time and, combined with a preset fume diffusion model, predict the main diffusion path of the fumes. Based on this prediction, the suction pipe, which is connected to the rotatable structure and the shell, can be precisely adjusted to the optimal angle, ensuring that the suction nozzle is always aimed at the area where the fumes are most concentrated, thereby maximizing the efficiency of fume capture and preventing fume escape.
[0052] Through the above technical solution, this control method enables refined and intelligent management of the high-power laser welding process. It overcomes the limitations of traditional fixed-parameter operation by dynamically adjusting the shielding gas flow, spatter interception airflow, and dust extraction pipe angle based on real-time welding status perception. This ensures that the molten pool remains in optimal protection under complex and variable welding conditions, while simultaneously ensuring efficient and thorough removal of fumes and spatter particles from the welding area. This dynamic adaptive control strategy significantly improves the stability of welding quality, equipment operating efficiency, and the safety of the operating environment.
[0053] In high-power laser welding, although the welding status can be monitored in real time and the gas flow rate adjusted using various sensors, failure to respond promptly and specifically to certain abnormal situations (such as excessively high molten pool temperature, excessive fume concentration, or excessive spatter impact) may lead to decreased welding quality, equipment damage, or operational safety hazards. Especially in complex and variable welding environments, the lack of intelligent judgment and coordinated control of key parameters makes it difficult to ensure the stability and reliability of the welding process.
[0054] In response, this application further proposes a control method in which, when the temperature sensor detects that the temperature of the molten pool is higher than a preset temperature threshold, the system will introduce nitrogen from the air inlet for pre-cooling; when the dust measurement sensor detects that the dust value is higher than a preset dust threshold, the system will activate the electrostatic adsorption module; and when the vibration sensor detects the splash impact force, the system will adjust the ventilation volume of the tangential vortex compressed air of the splash interception layer.
[0055] Specifically, the temperature sensor can be a non-contact or contact sensor such as an infrared thermometer or thermocouple, used to monitor the temperature of the molten pool in real time. The preset temperature threshold is determined comprehensively based on factors such as welding materials, welding processes, and equipment safety operation requirements. When the monitored molten pool temperature exceeds this threshold, the control system immediately triggers an actuator, such as a solenoid valve, to open the passage between the air inlet and the nitrogen source, introducing nitrogen into the welding area. As an inert gas, nitrogen not only effectively reduces the molten pool temperature, preventing material performance degradation due to overheating, but also provides an additional protective atmosphere to a certain extent, inhibiting oxidation reactions. This pre-cooling mechanism can proactively intervene to prevent the temperature from continuously rising and causing more serious welding defects.
[0056] The fume measurement sensor can be an optical scattering sensor or a particulate matter concentration sensor to monitor the fume concentration above the welding area in real time. A preset fume threshold is set based on environmental standards, welding quality requirements, and operator health factors. When the fume value detected by the fume measurement sensor exceeds this threshold, the control system sends a start command to the electrostatic adsorption module. The electrostatic adsorption module typically includes honeycomb electrode plates. By applying a high-voltage electric field, fume particles are charged and adsorbed onto the electrode plates, thereby efficiently removing welding fumes. This on-demand start strategy ensures rapid environmental purification when fume concentration is high, while avoiding continuous operation of the electrostatic adsorption module when fume concentration is low, thus reducing energy consumption.
[0057] The vibration sensor, which can be an accelerometer or a piezoelectric sensor, is installed near the spatter interception layer to detect the impact force of spatter particles generated during welding on the device in real time. The magnitude of the spatter impact force reflects the intensity and quantity of spatter. When the vibration sensor detects that the spatter impact force reaches or exceeds a preset value, the control system dynamically adjusts the airflow of the tangential vortex compressed air in the spatter interception layer according to the intensity of the impact force. For example, when the impact force is large, the airflow is increased to enhance the intensity of the tangential vortex, thereby more effectively capturing and intercepting spatter particles and preventing them from spreading or adhering to critical components. This adaptive adjustment mechanism ensures that the spatter interception layer maintains optimal interception performance under different spatter intensities.
[0058] Through the above technical solutions, this application enables precise and adaptive control of the high-power laser welding process. When the temperature sensor detects in real time that the molten pool temperature exceeds a preset threshold, the system can quickly introduce nitrogen gas from the air inlet for pre-cooling, effectively suppressing overheating of the molten pool and preventing material performance degradation, thereby ensuring welding quality and equipment safety. Simultaneously, once the fume measurement sensor detects that the fume concentration exceeds the threshold, the electrostatic adsorption module immediately activates, efficiently capturing charged fume particles, significantly improving the working environment and reducing contamination of optical components. Furthermore, the vibration sensor can sense the spatter impact force in real time and dynamically adjust the ventilation volume of the tangential vortex compressed air in the spatter interception layer accordingly, ensuring effective capture of spatter particles even when the spatter intensity changes, preventing adverse effects on the welding area and surrounding environment. This intelligent control strategy based on multi-sensor linkage feedback significantly improves the response speed and control accuracy of the device under complex welding conditions, ensuring the stability and reliability of the welding process.
[0059] In some embodiments described above, a control method for a multi-stage protection and dust extraction integrated device for high-power laser welding is proposed. This method introduces argon gas for primary protection, introduces tangential vortex compressed air to capture spatter particles, introduces helium gas to extend the molten pool cooling time, adjusts the gas flow rate based on sensor data, and dynamically adjusts the angle of the dust extraction pipe. However, in actual high-power laser welding processes, failure to accurately control the key parameters of the shielding gas and spatter interception gas may lead to insufficient molten pool protection, oxide layer formation, and low spatter particle capture efficiency, thereby affecting welding quality and equipment operational stability.
[0060] In response, this application further proposes the above-mentioned control method, wherein the argon gas introduced into the main protective layer has a purity of 99.999%, a flow rate of 25-35 L / min, and a coverage width of not less than 8 mm covering the core area of the molten pool; the pressure of the tangential vortex compressed air in the spatter interception layer is 0.6-1.0 MPa, and the angular velocity is greater than 3000 rad / s, which can capture spatter particles with a diameter greater than 10 μm.
[0061] Specifically, the argon gas introduced into the main protective layer has a purity of 99.999%, meaning that the argon gas used reaches an ultra-high purity level. In laser welding, especially high-power laser welding, the molten pool is extremely sensitive to reactive gases such as oxygen and nitrogen. Using 99.999% ultra-high purity argon gas can minimize the contact between the molten pool and reactive gases in the air, effectively suppressing adverse reactions such as oxidation and nitriding, thereby avoiding defects such as porosity and cracks in the weld and ensuring the mechanical properties and corrosion resistance of the weld. The argon gas flow rate is set within the range of 25-35 L / min, which is a key parameter optimized to ensure the formation of a stable and effective protective atmosphere. Too low a flow rate may result in incomplete coverage of the protective gas, failing to effectively isolate the air; too high a flow rate may cause airflow turbulence, drawing surrounding air into the molten pool area, thus undermining the protective effect and increasing gas consumption. This flow rate range can ensure the formation of a stable, laminar protective gas flow in the molten pool area while avoiding airflow disturbance, ensuring the protective effect, and taking into account gas utilization efficiency. Furthermore, the shielding gas coverage width over the core area of the molten pool should be no less than 8 mm. The core area of the molten pool is where laser energy is most concentrated, the temperature is highest, and oxidation reactions are most likely to occur. Ensuring that the shielding gas coverage width reaches or exceeds 8 mm means that the shielding gas can fully cover the entire molten pool and its surrounding heat-affected zone, providing a comprehensive physical barrier for the molten pool. This effectively prevents the molten pool from contacting the atmosphere before solidification, thereby significantly improving the oxidation resistance and weld formation quality.
[0062] For the spatter interception layer, the pressure of the tangential vortex compressed air is set at 0.6-1.0 MPa. This pressure range ensures that the compressed air has sufficient momentum and energy to form a strong tangential airflow and vortex within the spatter interception layer. This generates a strong centrifugal force and drag force on the spatter particles generated during welding, effectively capturing and guiding them to the dust extraction channel, preventing spatter particles from contaminating optical components or affecting weld quality. Simultaneously, the angular velocity of the tangential vortex compressed air is greater than 3000 rad / s. Angular velocity is a key parameter for measuring vortex strength and capture efficiency. An angular velocity greater than 3000 rad / s means that a high-speed rotating airflow field is formed within the spatter interception layer. This high-speed vortex exerts a strong centrifugal force on the spatter particles entering its area, causing them to quickly deviate from the welding area and be effectively intercepted. High angular velocity is particularly important for capturing fine spatter particles, significantly improving the overall efficiency of spatter interception. Through the optimized pressure and angular velocity described above, the spatter interception layer can efficiently capture spatter particles with a diameter greater than 10 μm. These larger-diameter spatter particles typically have the greatest impact on contamination of optical components and the formation of weld defects. Effectively capturing these particles can significantly reduce contamination in the welding area, protect the laser head and optical system, and reduce weld defect rates.
[0063] By precisely controlling the key parameters of the main shielding gas and the spatter interception gas through the above technical solutions, the protective effect and spatter capture efficiency of the high-power laser welding process can be significantly improved. Specifically, using 99.999% pure argon gas at a flow rate of 25-35 L / min, and ensuring that its coverage of the core area of the molten pool is not less than 8 mm, provides an extremely pure and stable protective environment for the molten pool, maximally suppressing molten pool oxidation and nitriding, thereby obtaining a high-quality weld with no porosity, no cracks, and excellent mechanical properties. Simultaneously, introducing tangential vortex compressed air with a pressure of 0.6-1.0 MPa and an angular velocity greater than 3000 rad / s through the spatter interception layer creates a strong and stable vortex airflow, efficiently capturing spatter particles larger than 10 μm in diameter. This effectively prevents spatter contamination of optical components and the welding area, ensuring long-term stable operation of the equipment and further improving the surface quality and consistency of the weld. These precise parameter controls work together to ensure the stability of the high-power laser welding process and the reliability of the welding quality.
[0064] The table above shows the test comparison data between the present invention and the conventional device.
[0065] Additionally, feedforward compensation can be performed using the following formula: Calculate the air curtain parameters based on welding power (P), plate thickness (t), and material reflectivity (R):
[0066] It should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A high-power laser welding multi-level protection and dust extraction integrated device, characterized in that, The device includes a housing, with a nozzle, an air inlet, and a dust extraction pipe installed at the bottom. Inside the housing, there is a main protection channel and a dust extraction channel communicating with the nozzle. One end of the dust extraction channel is connected to the dust extraction pipe, and the other end is connected to the inside of the suction nozzle. Inside the housing, there is a dust extraction module communicating with the channel. The housing is equipped with a temperature sensor, a dust measurement sensor, and a vibration sensor. A radar detector is installed on the top of the housing. A rear protection channel is formed between the nozzle and the side wall of the housing. The air inlet is connected to the gap channel. The diameter of the dust extraction channel is smaller than the inner diameter of the suction nozzle, so that the inside of the suction nozzle and the dust extraction channel form a Venturi suction structure. The housing has a fly-intercepting layer located above the dust extraction pipe. The dust extraction pipe is rotatably connected to the housing.
2. The high-power laser welding multi-level protection and dust extraction integrated device according to claim 1, characterized in that, The lower part of the housing is equipped with an electrostatic adsorption module, and the upper part of the suction nozzle passes through the electrostatic adsorption module and is connected to the housing.
3. The high-power laser welding multi-level protection and dust extraction integrated device according to claim 2, characterized in that, The electrostatic adsorption module is a honeycomb electrode plate.
4. The high-power laser welding multi-level protection and dust extraction integrated device according to claim 1, characterized in that, The interceptor layer includes a cavity with an internal arc-shaped surface, and the cavity sidewalls are provided with vents.
5. The high-power laser welding multi-level protection and dust extraction integrated device according to claim 1, characterized in that, The dust extraction module includes a miniature vortex fan, which is connected to the dust extraction channel.
6. The high-power laser welding multi-level protection and dust extraction integrated device according to claim 1, characterized in that, The housing contains a filter assembly located above the nozzle, which includes a sintered metal filter element and a ceramic fiber membrane.
7. A control method for a high-power laser welding multi-level protection and dust extraction integrated device based on any one of claims 1-6, characterized in that, Includes the following steps: Argon gas is introduced through the main protection channel, blown out from the nozzle, and covers the core area of the molten pool. Tangential vortex compressed air is introduced from the spatter interception layer to capture spatter particles, and helium gas is introduced from the air inlet and blown toward the molten pool to prolong the cooling time of the molten pool and suppress the formation of oxide layer. By drawing or blowing air into the dust extraction port, air is expelled from inside the dust extraction channel, creating a local negative pressure environment in the area above the nozzle. This is used to capture the smoke and dust above the molten pool in real time, and to capture charged particles through the electrostatic adsorption module. Based on real-time data detected by temperature sensors, dust measurement sensors, and vibration sensors, the ventilation volume of gas at different locations is adjusted. By scanning the welding path with radar, the trajectory of smoke and dust diffusion is predicted, and the angle of the dust extraction pipe is dynamically adjusted.
8. The control method according to claim 7, characterized in that, When the temperature sensor detects that the temperature of the molten pool is higher than the temperature threshold, nitrogen gas is introduced from the gas inlet for pre-cooling. When the dust measurement sensor detects that the dust level is higher than the dust threshold, the electrostatic adsorption module is activated. The vibration sensor detects the impact force of the splash and adjusts the ventilation volume of the tangential vortex compressed air in the splash interception layer.
9. The control method according to claim 7, characterized in that, The argon gas introduced into the main protective layer has a purity of 99.999%, a flow rate of 25-35 L / min, and a coverage width of ≥8 mm covering the core area of the molten pool; the tangential vortex compressed air of the spatter interception layer has a pressure of 0.6-1.0 MPa, an angular velocity of >3000 rad / s, and captures spatter particles with a diameter >10 μm.