A laser welding head module for automobile chassis parts

Abstract

The application discloses a laser welding joint module for automobile chassis parts, two groups of laser generators are vertically arranged in sequence along the welding direction of the laser welding joint module, the laser generator in the front adopts a threadless self-fusion laser welding mode and is specially used for completing the penetration and backing operation of the weld root, the laser generator in the rear adopts a thread filling laser welding mode and is specially used for completing the filling and surface covering operation of the weld; and the emission ends of the two groups of laser generators can be driven by the driving motor to make the driving motor drive the emission ends to make reciprocating swing motion in a range less than 180 degrees, laser swing welding is realized, welding precision and weld forming quality are considered, and the welding requirement of complex welds of automobile chassis parts is met.

Description

Technical Field

[0001] This invention relates to the field of technology, and more specifically to a laser welding head module for automotive chassis components. Background Technology

[0002] As the core load-bearing component of a vehicle, the chassis, including but not limited to frame longitudinal beams, cross beams, control arms, steering knuckles, and subframes, directly determines the vehicle's driving stability, handling safety, and overall service life. These components are mostly made of low-carbon steel, low-alloy steel, high-strength steel, and some aluminum alloys. Welding, as a core process in its production, places extremely high industry requirements on welding quality, efficiency, and stability.

[0003] Currently, the industry mainly focuses on process optimization to improve the welding quality of automotive chassis components. The core directions are divided into two categories: one is to use composite welding process, and the other is to use laser oscillation welding. However, both types of processes have obvious shortcomings and are difficult to fully adapt to the production needs of chassis components.

[0004] In existing technologies, composite welding processes are mainly divided into two types: One type is the single-laser two-stage welding process, which first uses wireless self-fusion laser welding to achieve root penetration, and then uses wire-filler laser welding to complete the weld filling and capping. This process requires repeating the same welding trajectory twice, which is not only inefficient and difficult to match the needs of high-volume, high-paced automated production of automotive chassis parts, but also prone to trajectory deviation during the two movements, resulting in uneven weld formation and increased welding deformation, thus increasing the manpower and cost of subsequent correction processes. In addition, due to the interval between the two welding processes, the molten pool of the first laser welding has completely cooled and solidified before the second laser welding is performed. At this time, obvious delamination interfaces are easily formed between the front and rear welds, leading to reduced weld bonding strength, welding defects such as incomplete fusion and slag inclusions, and reduced weld tensile strength, which cannot meet the core requirements of long-term load-bearing of automotive chassis parts.

[0005] Another type is the laser-arc hybrid welding process, which uses a laser and an electric arc arranged in series. The laser is responsible for root penetration, while the electric arc is responsible for filler wire and surface covering. Although this process can complete two processes in one pass, effectively improving welding efficiency, it has many inherent drawbacks: electromagnetic interference and arc light fluctuations are generated during arc welding, leading to a decrease in welding precision and making it difficult to meet the stringent dimensional and positional tolerance requirements of automotive chassis components; at the same time, arc welding is prone to spatter, fumes, and residual impurities, reducing weld purity and posing a risk of hydrogen embrittlement, which in turn affects the high strength and fatigue resistance of the weld, making it unsuitable for the long-term use scenarios where chassis components are subjected to alternating loads and impact loads; in addition, the fumes and arc light pollution generated by the arc can damage the production environment and increase the company's environmental treatment costs, which is inconsistent with the green and high-end development trend of the automotive manufacturing industry.

[0006] In existing technologies, conventional laser oscillation welding is mainly divided into two methods: optical galvanometer oscillation and robotic arm oscillation. Both methods have their own shortcomings and cannot be fully optimized simultaneously. While optical galvanometer oscillation offers advantages such as high-speed welding and the ability to achieve complex oscillation trajectories, it suffers from high equipment costs, easy galvanometer wear, difficult maintenance, and weak anti-interference capabilities. On the other hand, robotic arm oscillation is characterized by simple structure and low equipment costs, but it often involves the oscillation of the entire welding torch, resulting in drawbacks such as large inertia, slow response speed, poor welding accuracy, and instability during high-speed welding. Neither method can simultaneously meet the triple requirements of welding stability, equipment cost, and welding quality.

[0007] In summary, given the shortcomings of the existing welding processes and equipment, there is an urgent need for a welding device and process that can balance welding efficiency, welding precision, weld quality, and production flexibility, while also meeting green and environmental protection requirements, in order to meet the production needs of automotive chassis components. Summary of the Invention

[0008] The purpose of this invention is to provide a laser welding head module for automotive chassis components, so as to solve the defects of existing composite welding processes and laser oscillation welding.

[0009] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution: A laser welding head module for automotive chassis components includes: two sets of laser generators, vertically arranged on a support along the welding direction of the laser welding head module. Referring to the welding direction of the laser welding head module, the laser generator at the front is for wireless welding, and the laser generator at the rear is for wired welding. The housing of each laser generator is cylindrical and rotatably connected to the support in the vertical direction. The emitting ends of each laser generator are positioned offset from their own rotation axis. A drive motor is mounted on the support. A rotating shaft is located at the top of the housing of each laser generator along its own rotation axis. The drive shaft of the drive motor and the two rotating shafts are connected by a transmission mechanism, enabling the drive motor to drive the emitting ends to reciprocate within a range of less than 180°. The oscillation angle of the laser generator at the front is smaller than that of the laser generator at the rear.

[0010] Furthermore, the transmission mechanism includes a transmission disk, a first gear, and a second gear; wherein the transmission disk is driven to rotate by the drive motor, and a connecting column is perpendicularly disposed on the transmission disk at an eccentric position; the first gear is a sector gear, the central mounting part of the first gear is rotatably connected relative to the bracket, and a connecting rod is disposed on the central mounting part of the first gear along the center line outward, the connecting rod having a sliding groove along its own axis, the connecting column passing through the sliding groove and being able to slide along the sliding groove; the second gear is a disc gear, the second gear is disposed at the end of the rotating shaft corresponding to the laser generator, and the second gear meshes with the first gear corresponding to the transmission mechanism.

[0011] Furthermore, the two transmission mechanisms share a transmission disk, and the connecting column passes through the slide grooves of the two first gears in sequence; the end of the connecting column is provided with a limiting block, and the limiting block abuts against the first gear located above.

[0012] Furthermore, in the connecting rods of the two first gears, one of the connecting rods has a first through groove in the horizontal direction, and the other connecting rod passes through the first through groove, and the spacing of the first through groove is the same as the thickness of the connecting rod passing through it.

[0013] Furthermore, the distance between the central mounting portion of the first gear located at the front and the drive motor is greater than the distance between the central mounting portion of the first gear located at the rear and the drive motor, so that the swing angle of the laser generator located at the front is smaller than the swing angle of the laser generator located at the rear.

[0014] Furthermore, the bracket is provided with sleeves in the vertical direction for the installation positions of the two laser generators, and the housings of the two sets of laser generators pass through the corresponding sleeves. Each end of the sleeve is provided with a bearing that is interference-fitted with the sleeve and the housing, respectively.

[0015] Furthermore, all modules of the laser emitter are integrated on a mounting base, which is vertically disposed inside the housing. At least two sets of spring telescopic rods are provided between the mounting base and the housing. The housing has a threaded hole on the side near the mounting base along a direction perpendicular to the mounting base, and a bolt is threaded into the threaded hole. The end of the bolt abuts against the mounting base. The distance between the emitting end of the laser emitter and the rotation axis of the housing can be adjusted by adjusting the bolt.

[0016] Furthermore, a second through slot is formed at the bottom of the housing along the direction of the bottom radius, and the emitting end of the laser emitter passes through the second through slot.

[0017] Furthermore, all modules of the laser emitter are integrated on a base, which is vertically positioned. The bottom end of the base is hinged to the bottom end of the mounting base, and the top of the base is connected to the top of the mounting base by a tension spring. A ball screw pair is provided on the mounting base in the vertical direction, and a slider is provided on the nut of the ball screw pair. The slider abuts against the base, and the angle between the base and the mounting base is adjusted by the reciprocating motion of the slider.

[0018] Furthermore, an auxiliary bracket is provided on the housing of the laser generator located at the rear, the auxiliary bracket being used to install and fix the wire feeding nozzle of the wire feeding mechanism.

[0019] To address the aforementioned technical problems, the present invention further provides the following technical solution: Compared with the prior art, the present invention has the following advantages: Two sets of laser generators are arranged in series along the welding direction. The front set is for wireless welding to penetrate the root and make the base, while the rear set is for wire welding to fill and cover the surface. This allows two welding processes to be completed in one pass of the laser gun, eliminating the need for repeated movement and greatly improving welding efficiency. This is suitable for the high-volume, high-cycle automated production of automotive chassis parts. At the same time, the two welding processes are carried out continuously. The rear set is filled with wire welding before the molten pool of the first weld has completely cooled, which avoids weld delamination, improves weld bonding strength, reduces defects such as incomplete fusion and slag inclusions, ensures the tensile strength of the weld, and meets the long-term load-bearing requirements of chassis parts.

[0020] Furthermore, by using a drive motor in conjunction with a transmission mechanism, the emitting ends of the two laser generators are driven to swing synchronously back and forth, replacing the traditional optical galvanometer swing and robotic arm swing. This not only has the advantages of high-speed swing and high welding precision, but also avoids the problems of high cost, easy wear and tear, and difficult maintenance of optical galvanometers. At the same time, it overcomes the disadvantages of large swing inertia, slow response, and easy instability at high speed of robotic arms. It takes into account welding stability, equipment cost and welding quality, and the swing angle can be adapted to the needs of root pass and filler wire, further improving the weld formation quality. Attached Figure Description

[0021] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of a laser welding head module for automotive chassis components; Figure 2 This is a schematic diagram of the transmission mechanism; Figure 3 This is a schematic diagram of the internal structure of a laser generator; Figure 4 for Figure 3 A cross-sectional view of the laser generator shown; Figure 5 A schematic diagram of another embodiment of the laser generator; Figure 6 for Figure 5 A schematic diagram of the internal structure of the laser generator shown. Figure 7 for Figure 5 The image shows a cross-sectional view of the laser generator.

[0023] The labels in the diagram represent the following: 1-Laser generator, 2-Bracket, 3-Emitting end, 4-Rotating shaft, 5-Drive motor, 6-Transmission disc, 7-First gear, 8-Second gear, 9-Connecting column, 10-Connecting rod, 11-Slide groove, 12-Limiting block, 13-First through groove, 14-Sleeve, 15-Bearing, 16-Mounting base, 17-Spring telescopic rod, 18-Threaded hole, 19-Bolt, 20-Second through groove, 21-Base, 22-Ball screw pair, 23-Slider, 24-Auxiliary bracket, 25-Thread feeding nozzle. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] like Figure 1 As shown, this invention provides a specific implementation of a laser welding head module for automotive chassis components. The core of this invention is the vertical arrangement of two sets of laser generators 1 along the welding direction of the laser welding head module (i.e., the direction of movement during module operation). Using the welding direction of the laser welding head module as a reference, the laser generator 1 at the front adopts a wireless self-fusion laser welding mode, specifically designed for completing the root penetration and undercut work of the weld. The laser generator 1 at the rear adopts a wire-filling laser welding mode, specifically designed for completing the filling and cover work of the weld. Furthermore, the emitting ends 3 of the two sets of laser generators 1 can synchronously reciprocate under the drive of a drive motor 5, achieving laser oscillating welding, balancing welding accuracy and weld formation quality, and adapting to the welding requirements of complex welds in automotive chassis components.

[0026] The front laser generator 1 employs a wireless self-fusion welding method, eliminating the need for additional wire feeding. Relying on the high energy density of the laser itself, it melts through the joints and laps of the chassis components to be welded, forming a strong root weld and laying the foundation for subsequent filler and cover welds. The rear laser generator 1, in conjunction with the wire feeding mechanism, performs wired welding, precisely feeding the welding wire into the molten pool of the previous weld to complete the filler and cover weld, ensuring that the weld thickness and width meet the welding standards for automotive chassis components. This tandem dual-laser structure enables the completion of both the root welding and filler / cover weld processes in a single pass, eliminating the need for repeated passes along the same welding path. This significantly improves welding efficiency and effectively adapts to the demands of high-volume, high-paced automated production of automotive chassis components, solving the technical pain point of low efficiency in traditional single-laser welding performed in two separate passes.

[0027] Simultaneously, the two welding processes are carried out continuously. Before the molten pool of the root weld of the first process has completely cooled and solidified, the filler wire welding of the second process follows up in a timely manner, so that the two welds can be fully fused, effectively avoiding the occurrence of weld delamination, significantly improving the weld bonding force, reducing common welding defects such as lack of fusion, slag inclusion, and porosity, and ensuring that the tensile strength and fatigue strength of the weld meet the core requirements of long-term load bearing of automotive chassis components, making it suitable for chassis components to withstand alternating loads and impact loads during long-term vehicle operation.

[0028] Specifically, both sets of laser generators 1 are mounted on the same bracket 2. The housing of the laser generator 1 is cylindrical and is vertically connected to the bracket 2. The emitting ends 3 of the laser generator 1 are positioned off-center from their own rotation axis. A rotating shaft 4 is mounted on the top of the housing of the laser generator 1 along its own rotation axis. The rotating shaft 4 of the two sets of laser generators 1 is driven to rotate synchronously by a drive motor 5 mounted on the bracket 2. This synchronously drives the emitting ends 3 to perform reciprocating oscillating motion, thereby realizing laser oscillating welding, expanding the welding coverage area, and improving the uniformity of weld formation.

[0029] The drive shaft of the drive motor 5 and the two rotating shafts 4 are connected by a set of transmission mechanisms, which enables the drive motor 5 to drive the transmitter 3 to reciprocate within a range of less than 180°; and the swing angle of the laser generator 1 located in front is smaller than the swing angle of the laser generator 1 located behind.

[0030] Specifically, the swing angle of the wireless welding at the front is controlled between 30° and 60° to meet the narrow welding requirements of the root pass, while the swing angle of the wired welding at the rear is controlled between 60° and 120° to meet the wide welding requirements of the filler and cover passes, ensuring that the weld root is compact and the cover pass is flat and uniform.

[0031] The bracket 2 is made of high-strength aluminum alloy, which combines lightweight and structural stability. It can effectively support components such as laser generator 1, drive motor 5 and transmission mechanism, while avoiding the impact of vibration generated during welding on the operating accuracy of the equipment.

[0032] The casing is made of high-temperature and corrosion-resistant stainless steel, which can effectively protect the internal core components such as the laser emission module and cooling module, and extend the service life of the equipment.

[0033] The drive motor 5 is a servo drive motor, which has the advantages of adjustable speed, fast response speed and high control precision. It can accurately control the swing frequency and swing amplitude of the transmitter 3 and adapt to the welding needs of automotive chassis parts of different specifications and thicknesses.

[0034] For transmission mechanisms, such as Figure 2 As shown, this embodiment provides the following examples.

[0035] The transmission mechanism includes a transmission disc 6, a first gear 7, and a second gear 8. All three are made of high-strength alloy steel and undergo precision machining and heat treatment to ensure transmission accuracy and structural strength, and to avoid wear and deformation problems during long-term use.

[0036] The transmission disk 6 is driven to rotate by the drive motor 5. The transmission disk 6 has a connecting column 9 set vertically on itself at an eccentric position. The connecting column 9 and the transmission disk 6 are integrally formed. The surface of the connecting column 9 is smooth and polished to reduce sliding friction and ensure smooth transmission.

[0037] The first gear 7 is a sector gear, and the sector angle is designed according to the swing angle requirements of the launch end 3. The first gear 7 has a connecting rod 10 integrally formed on the central mounting part along the center line. The length of the connecting rod 10 is designed according to the transmission stroke requirements. The connecting rod 10 has a sliding groove 11 along its own axis. The sliding groove 11 is a rectangular through groove. The width of the sliding groove 11 matches the diameter of the connecting post 9. The connecting post 9 passes through the sliding groove 11 and can slide freely along the sliding groove 11. When the transmission disk 6 rotates around the drive shaft, the connecting post 9 makes a circular motion, which in turn drives the connecting rod 10 to swing back and forth around the central mounting part of the first gear 7, and finally drives the first gear 7 to swing back and forth.

[0038] The second gear 8 is fixedly installed at the end of the rotating shaft 4 of the corresponding laser generator 1 by a flat key. The flat key connection structure is simple, easy to disassemble and assemble, and reliable in transmission. The second gear 8 meshes with the first gear 7 of the corresponding transmission mechanism, and the meshing gap is controlled between 0.02-0.05mm to ensure transmission accuracy. When the first gear 7 swings back and forth, it can drive the second gear 8 to rotate synchronously, thereby driving the housing of the laser generator 1 to rotate around its own rotating axis, and finally realizing the reciprocating swing of the emitting end 3.

[0039] Furthermore, in order to simplify the overall structure of the equipment, reduce manufacturing costs, and ensure the oscillation synchronization of the two laser generator 1 emitting ends 3, the two transmission mechanisms share a single transmission disk 6. That is, a single transmission disk 6 simultaneously drives the movement of two sets of first gears 7 and second gears 8, eliminating the need for additional drive motors 5 and transmission disks 6. This effectively simplifies the equipment structure and reduces the equipment size and manufacturing costs. The connecting column 9 passes through the sliding grooves 11 of the two first gears 7 in sequence, enabling a single connecting column 9 to synchronously drive the two first gears 7 to oscillate, ensuring that the oscillation rhythm of the two emitting ends 3 is completely consistent and avoiding the problem of welding trajectory misalignment.

[0040] Furthermore, in order to ensure the stability of the transmission between the two sets of transmission mechanisms and to prevent the connecting column 9 from falling off from both ends of the slide groove 11 during the sliding process, thus affecting the transmission effect, a limiting block 12 is provided at the end of the connecting column 9. The limiting block 12 abuts against the first gear 7 located above, which plays an axial limiting role for the connecting column 9, ensuring that the connecting column 9 always slides within the slide groove 11, thus ensuring the stability and reliability of the transmission process.

[0041] Meanwhile, to prevent the connecting rods 10 of the two first gears 7 from interfering with each other during the swinging process and to ensure that the two first gears 7 can swing smoothly and synchronously, one of the connecting rods 10 of the two first gears 7 has a first through groove 13 in the horizontal direction, and the other connecting rod 10 passes through the first through groove 13. The spacing of the first through groove 13 is consistent with the thickness of the connecting rod 10 passing through it, so as to realize the staggered arrangement of the two connecting rods 10, so that the two connecting rods 10 do not interfere with each other during the swinging process; and it also plays a limiting role in the axial direction between the two connecting rods 10, further improving the smoothness and stability of the transmission.

[0042] In order to ensure that the swing angle of the laser generator 1 located in front is smaller than the swing angle of the laser generator 1 located behind, such as Figure 2 As shown, this embodiment provides the following examples.

[0043] The distance between the central mounting part of the first gear 7 located at the front and the drive motor 5 is greater than the distance between the central mounting part of the first gear 7 located at the rear and the drive motor 5. According to the lever principle, when the connecting column 9 makes the same circular motion stroke, the greater the distance between the central mounting part of the first gear 7 and the drive motor 5, the smaller the swing angle of the first gear 7, and vice versa. This can make the swing angle of the front laser generator 1 smaller than the swing angle of the rear laser generator 1.

[0044] Regarding the rotating structure between the laser generator 1 and the support 2, as shown in the figure, this embodiment provides the following example.

[0045] The bracket 2 is equipped with sleeves 14 in the vertical direction for the installation positions of the two laser generators 1. The housings of the two sets of laser generators 1 pass through the corresponding sleeves 14. Each end of the sleeve 14 is equipped with a bearing 15 that is interference-fitted with the sleeve 14 and the housing, respectively. This prevents loosening or misalignment during rotation. The bearings 15 can effectively reduce the friction between the housing and the sleeve 14 when the housing rotates, improve the smoothness and stability of the housing rotation, and at the same time play a role in positioning and supporting the housing, ensuring the installation accuracy of the laser generators 1, preventing the housing from tilting during rotation, and ensuring the accuracy of the laser emission direction.

[0046] In order to adjust the swing radius of laser generator 1, and thus the swing amplitude of emitter 3, to adapt to the welding requirements of automotive chassis parts of different specifications and thicknesses, and to improve the versatility and production flexibility of the equipment, such as... Figure 3 and Figure 4 As shown, this embodiment provides the following examples.

[0047] All functional modules of the laser generator 1 (including the laser emission module, cooling module, control module, etc.) are integrated on the mounting base 16. The mounting base 16 is vertically installed inside the housing. At least two sets of spring telescopic rods 17 are provided between the mounting base 16 and the housing. The spring telescopic rods 17 are symmetrically arranged on both sides of the mounting base 16. The two ends of the spring telescopic rods 17 are fixedly connected to the mounting base 16 and the housing, respectively. The housing has a threaded hole 18 on the side near the mounting base 16 along the direction perpendicular to the mounting base 16. A bolt 19 is threaded into the threaded hole 18. The end of the bolt 19 abuts against the mounting base 16.

[0048] By rotating the adjusting bolt 19, the mounting base 16 can be moved horizontally, thereby adjusting the distance between the emitting end 3 of the laser generator 1 and the rotating shaft of the housing. The larger the distance, the larger the swing radius of the emitting end 3 and the larger the swing amplitude. Conversely, the smaller the swing amplitude, the more flexible the swing amplitude can be adjusted to meet the welding requirements of chassis parts with different widths and thicknesses.

[0049] The mounting base 16 is made of high-temperature resistant insulating material, which can effectively protect the internal module and prevent high temperature and electromagnetic interference from affecting the normal operation of the module; and the end of the bolt 19 is provided with anti-slip rubber pad to prevent the bolt 19 from pressing on the mounting base 16 and causing damage to the mounting base 16.

[0050] Meanwhile, in order to provide sufficient space for the swing of the transmitter 3 and avoid the laser emission being blocked by the housing, and to ensure that the welding is carried out normally, a second through slot 20 is opened at the bottom of the housing along the direction of the bottom radius. The length of the second through slot 20 matches the maximum swing stroke of the transmitter 3. The transmitter 3 of the laser generator 1 passes through the second through slot 20. The width of the second through slot 20 is slightly larger than the diameter of the transmitter 3, which ensures that the transmitter 3 can swing freely, and also avoids that the gap is too large, which would cause the spatter and dust generated during the welding process to enter the housing and damage the internal modules.

[0051] Furthermore, the inner wall of the channel is provided with a high-temperature resistant protective layer. The high-temperature resistant protective layer is made of alumina ceramic material with a thickness of 1-2mm. Alumina ceramic has excellent high-temperature resistance and corrosion resistance, which can effectively block the high temperature (up to 1500℃ or more) generated during laser welding from damaging the shell, extending the service life of the device, and avoiding shell deformation caused by high temperature, which would affect the laser emission accuracy and welding quality.

[0052] To improve welding quality, the incident angle of the emitter 3 is adjusted, such as... Figures 5-7 As shown, this embodiment provides the following examples.

[0053] Based on the previous embodiment, all functional modules of the laser generator 1 (including the laser emission module, cooling module, control module, etc.) are integrated on the base 21. The base 21 is vertically installed inside the housing, and the bottom end of the base 21 is hinged to the bottom end of the mounting base 16. The top of the base 21 and the top of the mounting base 16 are connected by a tension spring. The tension spring is made of high-strength elastic material and has good elastic reset performance. It can play an elastic pulling role on the base 21 to ensure that the base 21 maintains a vertical posture in the unadjusted state, while buffering the impact force generated during the adjustment process and protecting the connection structure between the base 21 and the mounting base 16.

[0054] The mounting base 16 is fixedly equipped with a ball screw pair 22 along the vertical direction. The ball screw pair 22 is made of high-precision ball screw, which has the advantages of high transmission accuracy, low friction coefficient and smooth operation, and can realize precise micro-adjustment of the angle of the base 21. A slider 23 is fixedly installed on the nut of the ball screw pair 22. The slider 23 is made of wear-resistant alloy material and the surface is smooth and polished to reduce friction loss when in contact with the base 21. The slider 23 abuts against the side of the base 21, and the abutment is provided with an anti-slip and wear-resistant pad to avoid slippage during the adjustment process and ensure the reliability of the adjustment action.

[0055] By driving the ball screw pair 22 to work, the nut and slider 23 are driven to reciprocate in the vertical direction. During the movement, the slider 23 pushes the base 21 to rotate around the bottom hinge point, thereby adjusting the angle between the base 21 and the mounting base 16. This ultimately achieves precise adjustment of the incident angle of the laser generator 1, adapting to the welding needs of different positions and angles of automotive chassis parts, further improving welding flexibility and weld formation quality, and solving the technical pain point of the fixed incident angle of traditional laser welding heads, which makes it difficult to adapt to complex weld welding.

[0056] Specifically, the ball screw assembly 22 is positioned on the back of the mounting plate relative to the base 21. The mounting plate has a matching through groove corresponding to the movement trajectory of the nut of the ball screw assembly 22. The length of the through groove matches the maximum movement stroke of the nut, and the width matches the cross-sectional dimensions of the slider 23, ensuring that the slider 23 can pass through smoothly.

[0057] After passing through the slot, the slider 23 abuts against the side of the base 21. The contact parts between the slider 23 and the base 21 are all designed with a beveled structure. The bevel angle is precisely designed to smoothly convert the vertical reciprocating motion of the slider 23 into the rotational power of the base 21 around the hinge point, reducing the jamming and stress concentration during the adjustment process, improving the smoothness and accuracy of the angle adjustment, while increasing the contact area to avoid wear caused by excessive local force, extending the service life of the slider 23 and the base 21, and further ensuring the stability and reliability of the incident angle adjustment of the laser generator 1.

[0058] The laser welding head module used in this embodiment has undergone precise optimization design in terms of incident posture. Combining the different process requirements of wireless self-fusion root pass and wire-filling cover pass, the advantages of the two welding modes are maximized through differentiated incident angle settings, fundamentally improving weld quality and forming effect, as detailed below: The laser generator for wireless self-fusion welding always maintains a vertical incident posture, that is, the laser emission direction forms a 90° vertical angle with the welding surface of the automotive chassis parts to be welded. This design is based on the core process principle of laser self-fusion welding, which can achieve precise focusing and efficient transfer of energy.

[0059] When the laser is incident perpendicularly, the energy density is uniformly distributed along the weld cross-section without energy offset loss. The high energy density of the laser can be concentrated on the butt joint and lap joint interface at the root of the weld, ensuring uniform penetration of the entire cross-section at the root of the weld and effectively avoiding key defects such as incomplete penetration or insufficient penetration depth. This is crucial for automotive chassis components, as these components are subjected to alternating loads and impact loads during vehicle operation. The root of the weld, as the load-bearing core, must have sufficient structural strength and connection reliability. The perpendicular incident design is precisely to solidify the load-bearing foundation of the weld root and provide a flat and firm base for subsequent filling and covering processes.

[0060] The laser generator for wire-filled welding is set at an angle of about 10° relative to the normal of the workpiece surface. Its design principle closely matches the molten pool formation law and welding wire melting characteristics of wire-filled welding.

[0061] From a process logic perspective, an inclination angle of approximately 10° can avoid the overheating and burning of the welding wire and increased spatter caused by direct laser bombardment of the welding wire when the laser is incident vertically. It can also ensure that the laser focus is precisely applied to the bonding area between the welding wire and the previous molten pool, forming a synergistic effect of "laser preheating + welding wire filling". On the one hand, the inclined laser can preheat the welding wire in advance, reduce the difficulty of melting the welding wire, promote uniform melting of the welding wire, and enable the molten welding wire to fill the groove of the previous weld smoothly and fully, achieving a good metallurgical bond with the previous molten pool and avoiding defects such as weld delamination and lack of fusion. On the other hand, the inclined posture can change the stress state of the molten pool, expand the wetting range of the molten pool, and enable the molten pool metal to spread more evenly. This effectively improves the flatness and aesthetics of the weld cover, reduces common defects such as unevenness, undercut, and excessive excess height, and meets the requirements of automotive chassis components for weld appearance quality and dimensional accuracy. In addition, the 10° tilt angle can effectively suppress the generation of welding spatter, reduce the amount of spatter adhering to the surface of the weld or parts, reduce the workload of subsequent cleaning processes, and avoid weld slag inclusion defects caused by spatter, further improving weld purity, enhancing the fatigue resistance and corrosion resistance of the weld, and meeting the needs of automotive chassis parts for long-term outdoor use and to withstand complex working conditions.

[0062] It should be noted that the 10° tilt angle of the rear laser generator can be finely adjusted according to the material (such as high-strength steel, aluminum alloy), thickness and welding wire specifications of the chassis parts to be welded (the fine adjustment range is controlled between 8° and 12°). This ensures that the optimal filler wire effect and weld formation quality can be achieved under different working conditions, maximizing the filling and covering functions of wire-filler welding, and ultimately achieving a high-quality weld with "firm root and beautiful cover", which fully meets the welding technology requirements of automotive chassis parts.

[0063] For wire welding of the laser generator 1 located at the rear, such as Figure 1 As shown, this embodiment provides the following examples.

[0064] An auxiliary bracket 24 is provided on the housing of the rear laser generator 1. The auxiliary bracket 24 has an L-shaped structure, with its free end extending towards the laser emitting end 3. The auxiliary bracket 24 is used to install and fix the wire feeding nozzle 25 of the wire feeding mechanism. The installation position of the wire feeding nozzle 25 corresponds to the emitting end 3 of the rear laser generator 1, ensuring that the welding wire can be accurately fed into the weld pool. At the same time, the auxiliary bracket 24 swings synchronously with the housing, so that the wire feeding nozzle 25 and the emitting end 3 of the rear laser generator 1 swing synchronously, avoiding relative displacement between the wire feeding nozzle 25 and the emitting end 3, ensuring uniform wire filling and improving the weld filling quality.

[0065] This structure simplifies the installation of the wire feeding mechanism, eliminating the need for an additional independent swing mechanism to drive the wire feeding nozzle 25 to swing, thus reducing the overall complexity and manufacturing cost of the equipment. The wire feeding nozzle 25 is made of high-temperature resistant copper alloy, and its inner diameter matches the diameter of the welding wire, ensuring smooth wire feeding and avoiding problems such as wire jamming and wire breakage, thereby further improving welding stability.

[0066] The working process of this embodiment is as follows: When in use, the module is installed on the robotic arm of the automated welding equipment. According to the specifications of the automotive chassis parts to be welded and the welding requirements, the bolt 19 is adjusted to change the distance between the laser emitting end 3 and the housing rotation axis, thereby adjusting the swing amplitude of the two emitting ends 3 to ensure that the swing amplitude of the wireless welding in front is adapted to the root base width, and the swing amplitude of the wire welding in the rear is adapted to the filling and covering width. The wire feeding nozzle 25 of the wire feeding mechanism is installed on the auxiliary bracket 24, and the position of the wire feeding nozzle 25 is adjusted to align it with the rear emitting end 3.

[0067] Start the drive motor 5 and the two sets of laser generators 1. The drive motor 5 drives the transmission disk 6 to rotate. The connecting column 9 on the transmission disk 6 makes a circular motion, which in turn drives the two first gears 7 to swing back and forth around their respective central mounting parts. The first gear 7 drives the meshing second gear 8 to rotate. The second gear 8 drives the housing to rotate around the bearing 15 inside the sleeve 14, so that the emitting ends 3 of the two laser generators 1 swing back and forth synchronously.

[0068] The robotic arm drives the module to move along the welding trajectory. The laser generator 1 at the front completes the penetration and rooting of the weld root through wireless self-fusion welding, while the laser generator 1 at the rear completes the filling and capping of the weld through wire-filling welding. The two processes are carried out continuously. The wire is filled in the rear process before the molten pool of the front process has completely cooled, ensuring that the weld joint is tight and free from defects such as delamination and lack of fusion. At the same time, the wire feed nozzle 25 swings synchronously with the rear housing to ensure uniform wire filling and further improve the quality of the weld.

[0069] During the welding process, the bearing 15 inside the sleeve 14 reduces the friction of the housing rotation and ensures smooth swing; the high-temperature resistant protective layer blocks high temperature and protects the housing; the spring telescopic rod 17 acts as a buffer for the mounting base 16 to prevent welding vibration from affecting the laser emission accuracy.

[0070] The module in this embodiment has a compact structure and stable operation, which can effectively improve the welding efficiency and quality of automotive chassis components, reduce equipment costs and environmental protection investment, adapt to the needs of large-volume, high-quality production, and can be widely used in laser welding of various automotive chassis components such as frame longitudinal beams, cross beams, and control arms.

[0071] The module in this embodiment has a compact structure and stable operation, which can effectively improve the welding efficiency and quality of automotive chassis components, reduce equipment costs and environmental protection investment, adapt to the needs of large-volume, high-quality production, and can be widely used in laser welding of various automotive chassis components such as frame longitudinal beams, cross beams, and control arms.

[0072] The above embodiments are merely exemplary embodiments of this application and are not intended to limit this application. The scope of protection of this application is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to this application within its substance and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of this application.

Claims

1. A laser welding head module for automotive chassis components, characterized in that, include: Two sets of laser generators (1) are vertically mounted on the support (2) in sequence along the welding direction of the laser welding head module; With reference to the welding direction of the laser welding head module, the laser generator (1) located in front is for wireless welding, and the laser generator (1) located behind is for wired welding; the housing of the laser generator (1) is a cylindrical structure, the housing is rotatably connected to the support (2) in the vertical direction, and the emitting end (3) of the laser generator (1) is set off from its own rotation axis; A drive motor (5) is mounted on the bracket (2). A rotating shaft (4) is mounted on the top of the housing of the laser generator (1) along its own rotation axis. The drive shaft of the drive motor (5) and the two rotating shafts (4) are connected by a set of transmission mechanisms, so that the drive motor (5) can drive the emitting end (3) to perform reciprocating swing motion within a range of less than 180°. Furthermore, the swing angle of the laser generator (1) located in front is smaller than the swing angle of the laser generator (1) located behind.

2. The laser welding head module for automotive chassis components according to claim 1, characterized in that, The transmission mechanism includes a transmission disc (6), a first gear (7), and a second gear (8); The transmission disk (6) is driven to rotate by the drive motor (5), and the transmission disk (6) has a connecting column (9) perpendicular to itself at an eccentric position; The first gear (7) is a sector gear. The central mounting part of the first gear (7) is rotatably connected to the bracket (2). The first gear (7) has a connecting rod (10) arranged outward along the center line at the central mounting part. The connecting rod (10) has a sliding groove (11) along its own axis. The connecting column (9) passes through the sliding groove (11) and can slide along the sliding groove (11). The second gear (8) is a disc gear, which is located at the end of the shaft (4) corresponding to the laser generator (1), and meshes with the first gear (7) corresponding to the transmission mechanism.

3. The laser welding head module for automotive chassis components according to claim 2, characterized in that, The two transmission mechanisms share a transmission disc (6), and the connecting column (9) passes through the groove (11) of the two first gears (7) in sequence; The end of the connecting column (9) is provided with a limiting block (12), which abuts against the first gear (7) located above.

4. The laser welding head module for automotive chassis components according to claim 3, characterized in that, Of the two connecting rods (10) of the first gear (7), one of the connecting rods (10) has a first through slot (13) in the horizontal direction, and the other connecting rod (10) passes through the first through slot (13), and the spacing of the through slot is consistent with the thickness of the connecting rod (10) passing through it.

5. The laser welding head module for automotive chassis components according to claim 4, characterized in that, The distance between the central mounting part of the first gear (7) located in front and the drive motor (5) is greater than the distance between the central mounting part of the first gear (7) located in the rear and the drive motor (5), so that the swing angle of the laser generator (1) located in front is smaller than the swing angle of the laser generator (1) located in the rear.

6. The laser welding head module for automotive chassis components according to claim 1, characterized in that, The bracket (2) is provided with sleeves (14) in the vertical direction at the installation positions of the two laser generators (1). The housings of the two sets of laser generators (1) pass through the corresponding sleeves (14). Both ends of the sleeves (14) are provided with bearings (15) that are interference fit with the sleeves (14) and the housings, respectively.

7. The laser welding head module for automotive chassis components according to claim 1, characterized in that, All modules of the laser emitter are integrated on the mounting base (16), which is vertically arranged inside the housing. At least two sets of spring telescopic rods (17) are provided between the mounting base (16) and the housing. The housing has a threaded hole (18) on the side near the mounting base (16) in a direction perpendicular to the mounting base (16). A bolt (19) is threadedly connected to the threaded hole (18), and the end of the bolt (19) abuts against the mounting base (16). The distance between the emitting end (3) of the laser emitter and the rotating shaft of the housing can be adjusted by adjusting the bolt (19).

8. The laser welding head module for automotive chassis components according to claim 7, characterized in that, The bottom of the housing has a second through slot (20) along the direction of the bottom radius, and the emitting end (3) of the laser emitter passes through the second through slot (20).

9. The laser welding head module for automotive chassis components according to claim 8, characterized in that, All modules of the laser emitter are integrated on the base (21), which is vertically arranged. The bottom end of the base (21) is hinged to the bottom end of the mounting base (16), and the top of the base (21) is connected to the top of the mounting base (16) by a tension spring. The mounting base (16) is provided with a ball screw pair (22) in the vertical direction. A slider (23) is provided on the nut of the ball screw pair (22). The slider (23) abuts against the base (21). The angle between the base (21) and the mounting base (16) is adjusted by the reciprocating motion of the slider (23).

10. The laser welding head module for automotive chassis components according to claim 1, characterized in that, An auxiliary bracket (24) is provided on the housing of the laser generator (1) located at the rear. The auxiliary bracket (24) is used to install and fix the wire feeding nozzle (25) of the wire feeding mechanism.

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