A laser welding system, method and apparatus

Abstract

The embodiment of the application provides a laser welding system, method and device, and relates to the field of laser processing.The system is composed of a welding gun, a control host and a power supply to form a welding structure, which eliminates the large rack required by a traditional fixed pattern welding system, solves the defects of the traditional fixed equipment being heavy and the operation scene being limited, and generates a welding path by means of the host MCU judging a pattern welding mode through a double-MCU communication architecture of the host MCU and the welding gun MCU, relies on the host MCU to generate a welding path, matches the stable transmission of the laser beam through the optical fiber, and collimates the laser with the help of the collimating lens.The collimated welding laser is transmitted to the focusing lens through the double-mirror scanning module, the focusing lens focuses the laser, and the welding gun MCU controls the deflection of the light path of the double-mirror scanning module, so that the laser focal point completes pattern welding on the workpiece surface according to the trajectory.This setting takes into account the simplicity of the equipment and the performance of complex pattern welding, adapts to diversified processing scenes, and improves the problem of low efficiency of traditional laser welding operation.

Description

Technical Field

[0001] This application relates to the field of laser processing, and more particularly to a laser welding system, method and apparatus. Background Technology

[0002] Laser welding uses a high-energy-density laser beam as a heat source to instantly melt local areas of the workpiece and form a strong weld. Laser welding technology has been widely applied in many key areas of manufacturing and has become an indispensable and important supporting technology for promoting the high-quality development of modern industry.

[0003] In existing technologies, the workpiece is usually fixed on a worktable, and the equipment control system adjusts the emission direction and travel path of the laser beam so that the laser beam completes scanning and traversing the workpiece surface according to a preset trajectory, thereby achieving laser welding.

[0004] However, existing technologies suffer from low laser welding efficiency. Current welding systems are limited in function and rely on large frames and precision tooling, failing to meet the combined demands of portability, low cost, and the ability to weld complex patterns in flexible manufacturing scenarios, resulting in low laser welding efficiency. Summary of the Invention

[0005] This application provides a laser welding system, method, and apparatus to solve the problem of low efficiency in existing laser welding technologies.

[0006] In a first aspect, embodiments of this application provide a laser welding system, including: a welding torch, a control host, and an AC power supply electrically connected to the welding torch and the control host. The control host includes a host MCU and a welding laser, and the welding torch includes a welding torch MCU, a collimating lens, a focusing lens, and a dual-galvanometer scanning module.

[0007] Both the welding torch MCU and the welding laser are communicatively connected to the host MCU. The welding laser is connected to the collimating lens via an optical fiber. The dual galvanometer scanning module is communicatively connected to the welding torch MCU.

[0008] The host MCU is used to acquire mode signals. If the welding mode is determined to be a graphic welding mode based on the mode signals, the host MCU acquires the welding graphic and welding parameters, generates a welding path according to the welding graphic, and sends the welding path to the welding gun MCU.

[0009] The host MCU is also used to respond to welding commands, control the welding laser to transmit welding laser to the collimating lens based on the welding parameters, the collimating lens is used to collimate the welding laser to obtain a collimated welding laser, and transmit the collimated welding laser to the focusing lens through the dual galvanometer scanning module, the focusing lens is used to focus the collimated welding laser to obtain a focused welding laser;

[0010] The welding torch MCU is used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focal point of the focused welding laser welds on the workpiece surface according to the welding path.

[0011] In one possible design, the welding torch is provided with a multi-function button area, which includes a welding start button and a mode knob. Both the welding start button and the mode knob are connected to the host MCU via the welding torch MCU.

[0012] The host MCU is also used to control the welding laser to switch from the shutdown state to the welding ready state in response to the welding start button being pressed;

[0013] The welding torch MCU is also used to acquire the state of the mode knob and generate the mode signal based on the state; wherein the mode signal is used to represent the welding mode, which is the graphic welding mode, continuous welding mode or spot welding mode.

[0014] In one possible design, the control host is also equipped with a preview laser, which is communicatively connected to the host MCU. The preview laser is connected to the collimating lens via an optical fiber. The multi-function button area is also equipped with a two-stage trigger button, which is connected to the signal line of the host MCU.

[0015] The host MCU is also configured to, in response to the first press of the two-stage trigger button, control the preview laser to transmit the preview laser to the collimating lens through an optical fiber based on preset preview parameters. The collimating lens is used to collimate the preview laser to obtain a collimated preview laser, and transmit the collimated preview laser to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated preview laser to obtain a focused preview laser.

[0016] The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused preview laser to scan the welding path on the workpiece surface;

[0017] The host MCU is also configured to control the welding laser to transmit welding laser to the collimating lens based on the welding parameters in response to the second pressing of the two-stage trigger button; wherein, the welding command refers to the second pressing of the two-stage trigger button, and the second pressing of the two-stage trigger button is used to indicate that the welding path scanned on the surface of the workpiece is correct.

[0018] In one possible design, when the host MCU determines that the welding mode is a pattern welding mode based on the mode signal, it specifically performs the following functions:

[0019] Obtain the welding pattern, the type of material required for welding, and the welding thickness;

[0020] The matching degree between the welding pattern, the type of material required for welding, and the welding thickness and multiple preset parameter packages is calculated, and the parameters in the preset parameter package corresponding to the maximum matching degree are determined as the welding parameters; wherein, the welding parameters include initial laser power, initial pulse frequency, initial duty cycle, and initial scanning speed.

[0021] In one possible design, the welding torch MCU is used to acquire the real-time welding speed and send the real-time welding speed to the host MCU;

[0022] The host MCU is also used to acquire real-time laser power and real-time pulse frequency, and adjust the real-time laser power and real-time pulse frequency according to the real-time welding speed so that the laser energy per unit length of weld is constant.

[0023] In one possible design, the welding torch MCU is also used to acquire the real-time attitude of the welding torch during the welding process and the initial attitude of the welding torch before welding begins, and send the real-time attitude and the initial attitude to the host MCU;

[0024] The host MCU is also used to calculate the welding gun attitude offset based on the real-time attitude and the initial attitude. If the welding gun attitude offset is less than or equal to a preset offset threshold, the welding path is corrected based on the welding gun attitude offset to obtain a corrected welding path, and the corrected welding path is sent to the welding gun MCU.

[0025] The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focus of the focused welding laser welds on the workpiece surface according to the corrected welding path.

[0026] In one possible design, the laser welding system further includes a rectifier power supply, a first step-down circuit, a second step-down circuit, and a third step-down circuit. The AC power supply and the welding laser are both electrically connected to the rectifier power supply. The AC power supply and the second step-down circuit are both electrically connected to the first step-down circuit. The second step-down circuit is electrically connected to the host MCU. The first step-down circuit and the welding torch MCU are both electrically connected to the third step-down circuit.

[0027] The welding torch MCU is also used to acquire the temperature of the welding torch and the first fluctuation amplitude of the output power of the rectifier power supply, and send the first fluctuation amplitude to the host MCU;

[0028] The welding torch MCU is also used to send a first alarm signal to the host MCU when the welding torch attitude offset is greater than a preset offset threshold or the temperature is greater than a preset temperature threshold.

[0029] The host MCU is also used to obtain the second fluctuation amplitude of the real-time laser power, and generate a second alarm signal when the first fluctuation amplitude is greater than a preset first amplitude threshold or the second fluctuation amplitude is greater than a preset second amplitude threshold.

[0030] The host MCU is also used to trigger preset protection measures corresponding to the alarm type based on the alarm type of the first alarm signal and the second alarm signal.

[0031] In one possible design, the laser welding system further includes a fourth step-down circuit. The dual galvanometer scanning module includes a galvanometer motor. The galvanometer motor and the first step-down circuit are both electrically connected to the fourth step-down circuit. The welding torch is provided with a welding torch housing and a welding torch air duct. The control host is provided with a host housing, a host air duct, and a fan. The fan is electrically connected to the host MCU. The host MCU is used to output a PWM speed control signal to the fan to adjust the fan speed.

[0032] The first air inlet and the first air outlet of the welding torch air duct are both located on the welding torch housing. External air enters the welding torch air duct from the first air inlet, flows through the sealed housing of the galvanometer motor, collimating lens and focusing lens, and then exits the welding torch air duct from the first air outlet.

[0033] The second air inlet and the second air outlet of the host air duct are both located on the host housing. The fan is located inside the host air duct. The fan is used to draw in external air and deliver the external air to the welding laser through the airflow generated by the fan rotation. The external air is used to absorb the heat of the welding laser and then discharged from the host air duct through the second air outlet.

[0034] In one possible design, the welding laser is equipped with a temperature sensor, which is electrically connected to the host MCU. The temperature sensor is used to collect the temperature signal of the welding laser, convert the temperature signal into an analog voltage, and send the analog voltage to the host MCU. The host MCU is used to convert the analog voltage into temperature and adjust the speed of the fan according to the temperature.

[0035] In one possible design, the welding torch MCU is also configured to send a welding completion signal to the host MCU in response to the fact that the focus of the focused welding laser has traversed the welding path.

[0036] The host MCU is also used to control the welding laser to stop operating in response to the welding completion signal.

[0037] In one possible design, the welding torch is equipped with a status indicator module, which is connected to the welding torch MCU signal line. The welding torch MCU is also used for:

[0038] In response to the AC power supply starting to power the first step-down circuit, the status indicator module is controlled to output a power-on light prompt.

[0039] In response to the welding laser switching from the shutdown state to the welding standby state, the status indicator module is controlled to output a standby status light prompt.

[0040] In response to the first alarm signal or the second alarm signal, the status indicator module is controlled to output a fault alarm light prompt.

[0041] In response to the welding completion signal, the status indicator module is controlled to output a light prompt indicating that the job is completed.

[0042] In a second aspect, embodiments of this application provide a laser welding method, the method being applied to a host MCU in a laser welding system as described in any of the first aspects, the method comprising:

[0043] The mode signal is acquired. If the welding mode is determined to be a graphic welding mode based on the mode signal, the welding graphic and welding parameters are acquired. A welding path is generated according to the welding graphic and the welding path is sent to the welding gun MCU. The welding gun MCU and the welding laser are both communicatively connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber. The dual galvanometer scanning module is communicatively connected to the welding gun MCU.

[0044] In response to a welding command, the welding laser is controlled to transmit welding laser light through an optical fiber to the collimating lens based on the welding parameters. The collimating lens is used to collimate the welding laser light to obtain a collimated welding laser light. The collimated welding laser light is then transmitted to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated welding laser light to obtain a focused welding laser light. The welding torch MCU is used to control the dual galvanometer scanning module to deflect the optical path of the focused welding laser light so that the focal point of the focused welding laser light is aligned with the welding path on the workpiece surface for welding.

[0045] Thirdly, embodiments of this application provide a laser welding apparatus, the apparatus being located in a host MCU within a laser welding system as described in any of the first aspects, the apparatus comprising:

[0046] The acquisition module is used to acquire mode signals. If the welding mode is determined to be a graphic welding mode based on the mode signals, the welding graphic and welding parameters are acquired, a welding path is generated according to the welding graphic, and the welding path is sent to the welding torch MCU. The welding torch MCU and the welding laser are both communicatively connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber, and the dual galvanometer scanning module is communicatively connected to the welding torch MCU.

[0047] A control module, in response to a welding command, controls the welding laser to transmit welding laser light through an optical fiber to the collimating lens based on the welding parameters. The collimating lens collimates the welding laser light to obtain a collimated welding laser, and transmits the collimated welding laser light to the focusing lens through the dual-galvanometer scanning module. The focusing lens focuses the collimated welding laser light to obtain a focused welding laser. The welding torch MCU controls the dual-galvanometer scanning module to deflect the focused welding laser light path so that the focal point of the focused welding laser light welds onto the workpiece surface according to the welding path.

[0048] This application provides a laser welding system, method, and apparatus. By integrating a welding torch, control host, and power supply into a single welding structure, it eliminates the need for the large frame and precision tooling required by traditional fixed pattern welding systems. This simplifies the equipment structure, reduces manufacturing costs, and eliminates the need to transport workpieces to a fixed processing station for welding. This solves the problems of bulky and limited operating scenarios of traditional fixed equipment. Furthermore, by configuring a dual-MCU communication architecture between the host MCU and the welding torch MCU, the host MCU determines the pattern welding mode and autonomously generates the welding path. A stable laser beam is transmitted via fiber optic cable, and a collimating lens is used to collimate the laser. The collimated welding laser is then transmitted to a focusing lens via a dual-galvanometer scanning module. The focusing lens focuses the laser, and the welding torch MCU precisely controls the dual-galvanometer scanning module to deflect the optical path, ensuring that the laser focus strictly follows a preset trajectory to complete complex pattern welding on the workpiece surface. This overcomes the shortcomings of traditional welding methods in processing complex welds. Based on this hardware structure and control logic, it balances equipment simplicity with complex pattern welding performance, adapting to diverse and flexible processing scenarios and improving the low efficiency of traditional laser welding operations. Attached Figure Description

[0049] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0050] Figure 1 A schematic flowchart of the laser welding method provided in the embodiments of this application;

[0051] Figure 2 This is a schematic diagram of the structure of the laser welding apparatus provided in the embodiments of this application;

[0052] Figure 3 This is a schematic diagram of the hardware structure of the electronic device provided in the embodiments of this application.

[0053] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0054] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0055] In the embodiments of this application, the terms "first" and "second" are used to distinguish identical or similar items with substantially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and that "first" and "second" do not necessarily imply difference. It should be noted that in the embodiments of this application, words such as "exemplary" or "for example" are used to indicate examples, illustrations, or explanations. Any embodiment or design scheme described as "exemplary" or "for example" in this application should not be construed as being more preferred or advantageous than other embodiments or design schemes. Specifically, the use of words such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner. In the embodiments of this application, "at least one" refers to one or more, and "more than one" refers to two or more.

[0056] It should be noted that the phrase "at...time" in the embodiments of this application can refer to the instant at which a certain situation occurs, or to a period of time after the occurrence of a certain situation; the embodiments of this application do not specifically limit this. Furthermore, the laser welding system, method, and apparatus provided in the embodiments of this application are merely examples; a laser welding system, method, and apparatus may also include more or fewer elements.

[0057] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of the present invention will now be described with reference to the accompanying drawings.

[0058] To clearly understand the technical solution of this application, the solutions of the prior art will first be described in detail. Laser welding can use a high-energy-density laser beam as a heat source to instantly melt a local area of ​​the workpiece and form a strong weld. Laser welding technology has been widely applied in many key areas of manufacturing, becoming an indispensable and important supporting technology for promoting the high-quality development of modern industry.

[0059] In existing technologies, the workpiece is typically fixed on a worktable, and the equipment control system adjusts the laser beam's emission direction and path, causing the laser beam to scan and traverse the workpiece surface according to a preset trajectory, thus achieving laser welding. However, traditional fixed pattern welding systems rely on large frames and precision tooling, making the equipment bulky, expensive, and requiring the workpiece to be transported to a machining center, which is unsuitable for on-site operations. Traditional handheld laser welding machines, on the other hand, have limited functionality, supporting only spot welding or simple straight-line welding, failing to meet the combined demands of portability, low cost, and complex pattern welding capabilities in flexible processing scenarios, resulting in limited laser welding efficiency. Therefore, existing technologies suffer from low laser welding efficiency.

[0060] Therefore, to address the low efficiency of laser welding in existing technologies, the research found that, to solve this problem: Optionally, the dual-galvanometer scanning module, originally used in fixed equipment, can be directly installed into the movable welding torch housing. This allows the welding torch to point at the workpiece while the internal dual-galvanometer scanning module automatically controls the deflection of the laser beam, drawing complex patterns on the workpiece surface without moving the workpiece or relying on an external motion platform, thus shortening workpiece clamping and handling time. Optionally, path generation and laser control tasks can be assigned to the host MCU within the control unit, while the real-time trajectory execution task of the galvanometer can be assigned to the welding torch MCU. The two are communicatively connected; the host MCU calculates the welding path based on the user-input pattern and sends it to the welding torch MCU, which is then dedicated to driving the galvanometer to deflect along the path. Optionally, a collimating lens can be installed at the fiber optic output end inside the welding torch to first convert the divergent laser output from the fiber optic into parallel light, which is then transmitted to the dual galvanometer scanning module behind it. The light is then focused into a small spot by a focusing lens. This ensures the quality of the parallel beam required for galvanometer scanning and also makes the optical module miniaturized, allowing it to be installed in the welding torch along with the galvanometer. This enables handheld devices to achieve high-quality pattern welding and avoids the problems of slow welding speed and repeated re-welding caused by excessively large spot size or energy dispersion.

[0061] This application provides a laser welding system, method, and apparatus. By integrating a welding torch, control host, and power supply into a single welding structure, it eliminates the need for the large frame and precision tooling required by traditional fixed pattern welding systems. This simplifies the equipment structure, reduces manufacturing costs, and eliminates the need to transport workpieces to a fixed processing station for welding. This solves the problems of bulky and limited operating scenarios of traditional fixed equipment. Furthermore, by configuring a dual-MCU communication architecture between the host MCU and the welding torch MCU, the host MCU determines the pattern welding mode and autonomously generates the welding path. A stable laser beam is transmitted via fiber optic cable, and a collimating lens is used to collimate the laser. The collimated welding laser is then transmitted to a focusing lens via a dual-galvanometer scanning module. The focusing lens focuses the laser, and the welding torch MCU precisely controls the dual-galvanometer scanning module to deflect the optical path, ensuring that the laser focus strictly follows a preset trajectory to complete complex pattern welding on the workpiece surface. This overcomes the shortcomings of traditional welding methods in processing complex welds. Based on this hardware structure and control logic, it balances equipment simplicity with complex pattern welding performance, adapting to diverse and flexible processing scenarios and improving the low efficiency of traditional laser welding operations.

[0062] Based on the above-mentioned inventive discovery, the technical solution of this application is proposed.

[0063] This application provides a laser welding system, including: a welding torch, a control host, and an AC power supply electrically connected to the welding torch and the control host. The control host includes a host MCU and a welding laser, and the welding torch includes a welding torch MCU, a collimating lens, a focusing lens, and a dual-galvanometer scanning module.

[0064] Both the welding torch MCU and the welding laser are connected to the host MCU. The welding laser is connected to the collimating lens via optical fiber, and the dual galvanometer scanning module is connected to the welding torch MCU.

[0065] Specifically, a serial communication line can be used to achieve signal communication between the welding torch MCU and the host MCU, a control cable can be used to achieve command docking between the welding laser and the host MCU, and a transmission optical fiber can be used to establish a laser optical path connection between the welding laser and the collimating lens. Then, an internal cable can be used to complete the electrical docking between the dual galvanometer scanning module and the welding torch MCU. This setup is used to build a stable signal transmission and laser transmission path between the various components, allowing the host MCU to receive the mode signal from the welding torch MCU and send control commands to the welding laser. It also allows the welding torch MCU to independently control the dual galvanometer scanning module, while ensuring that the laser output from the welding laser can be smoothly transmitted to the collimating lens for optical path processing.

[0066] The host MCU is used to acquire mode signals. If the welding mode is determined to be graphic welding mode based on the mode signals, the welding graphic and welding parameters are acquired, the welding path is generated according to the welding graphic, and the welding path is sent to the welding gun MCU.

[0067] Specifically, after the host MCU receives the mode signal, it can identify and lock the pattern welding mode, and simultaneously read information such as the welding pattern, welding material type, and welding thickness. This information is then compared item by item with multiple pre-stored preset parameter packages. The preset parameter package with the highest matching degree is selected, and the initial laser power, initial pulse frequency, initial duty cycle, and initial scanning speed are extracted as welding parameters. Then, feature inflection points, line segment endpoints, and arc tangent points are selected sequentially along the outer contour and internal texture of the welding pattern. All selected points are then connected in sequence according to the continuous direction of the pattern to form a complete and continuous welding path. The welding path is then sent to the welding torch MCU. This setting is used to match the welding parameters based on the welding pattern, material type, and welding thickness, and to regularize a continuous and feasible welding path according to the actual contour characteristics of the welding pattern.

[0068] The host MCU is also used to respond to welding commands and control the welding laser to transmit welding laser to the collimating lens based on welding parameters. The collimating lens is used to collimate the welding laser to obtain a collimated welding laser. The collimated welding laser is then transmitted to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated welding laser to obtain a focused welding laser.

[0069] Specifically, after the host MCU receives the welding command, it can retrieve the predetermined initial laser power, initial pulse frequency, initial duty cycle, and initial scanning speed, and send corresponding level control signals to the welding laser. This allows the welding laser to output a reference laser beam according to these welding parameters. The reference laser beam is then directly fed into the collimating lens at the welding torch end via an internal optical fiber. The collimating lens gathers the diverging beam and transmits it to the focusing lens through the dual-galvanometer scanning module. The focusing lens gathers the beam to form a small spot, and the processed, well-defined laser beam is directly scanned onto the workpiece surface. This setup is used to regulate the laser's output state according to the matched parameters. The collimating lens and focusing lens are used to trim the original laser beam, providing the dual-galvanometer scanning module with a well-defined and energy-concentrated incident beam.

[0070] The welding laser is transmitted through an optical fiber to a collimating lens, which collimates the laser to obtain a collimated welding laser. The collimated welding laser is then transmitted to a dual-mirror scanning module, which controls the laser path by mechanically deflecting the reflecting mirrors, causing the laser focus to move along the welding path.

[0071] The welding torch MCU is used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focus of the focused welding laser is aligned with the welding path to weld on the workpiece surface.

[0072] Specifically, after the welding torch MCU receives the welding path data sent by the host MCU, it outputs the corresponding drive level to the two deflection motors inside the dual galvanometer scanning module, causing the internal reflector to shift at an angle, continuously changing the propagation direction of the focused welding laser, so that the laser focus stops and travels continuously along a predetermined path on the workpiece surface, conforming to the graphic contour to complete the welding operation. This setting is used to continuously adjust the laser emission angle according to the received path data, so that the laser focus moves in an orderly manner on the workpiece surface in accordance with the graphic contour, completing the welding processing of the corresponding trajectory.

[0073] In the application of laser welding systems, the welding torch and the control host are connected through a communication line. The host MCU is responsible for generating the graphic path and controlling the laser parameters, while the welding torch MCU is responsible for executing the real-time trajectory of the galvanometer. The two work together: the host MCU calculates the welding path based on the graphic input by the user and sends it to the welding torch MCU, which then drives the galvanometer to deflect the laser focus along the path. This architecture reduces the size of the equipment and improves the real-time performance and accuracy of graphic welding.

[0074] The host MCU is responsible for generating the graphic path and controlling laser parameters (such as matching parameter packages based on the welding graphic, material type, and thickness), while the welding torch MCU is responsible for executing the galvanometer's real-time trajectory (such as driving the dual galvanometer scanning module to deflect the optical path). The two interact in real time via a serial communication line. The host MCU sends the welding path to the welding torch MCU, which then drives the galvanometer motor to adjust the reflector angle based on the path data, ensuring that the laser focus strictly matches the graphic contour.

[0075] Laser welding systems can be applied to industrial processing scenarios such as precision component packaging, on-site equipment assembly and repair, and partial steel structure docking. They are suitable for various work occasions, including routine batch processing in workshops, on-site in-situ repair, and welding of irregular and complex textures. They can meet the processing needs of point welding, continuous linear welding, or welding of arbitrary complex graphic trajectories. They are suitable for welding operations of various metal materials and workpieces of different thicknesses. This system can solve the technical problems of traditional fixed welding equipment, such as large size, reliance on special tooling stations, and the need for workpiece transfer and hoisting. Conventional welding equipment has a single function and can only achieve simple trajectory processing, and cannot take into account site adaptability, ease of use, and the ability to weld complex graphics.

[0076] This embodiment provides a laser welding system that integrates a welding torch, a control host, and a power supply into a single welding structure. This eliminates the need for the large frame and precision tooling required in traditional fixed pattern welding systems, simplifying the equipment structure and reducing manufacturing costs. Welding can be completed without transporting the workpiece to a fixed processing station, overcoming the shortcomings of traditional fixed equipment that is bulky and has limited operating scenarios. By configuring a dual-MCU communication architecture between the host MCU and the welding torch MCU, the host MCU determines the pattern welding mode and autonomously generates the welding path. It uses fiber optics to stably transmit the laser beam, and then uses a collimating lens to collimate the laser. The collimated welding laser is transmitted to a focusing lens through a dual-galvanometer scanning module. The focusing lens focuses the laser, and the welding torch MCU precisely controls the dual-galvanometer scanning module to deflect the optical path, ensuring that the laser focus strictly follows a preset trajectory to complete complex pattern welding on the workpiece surface. This overcomes the shortcomings of traditional welding methods in processing complex welds. Based on this hardware structure and control logic, it balances equipment simplicity with complex pattern welding performance, adapts to diverse and flexible processing scenarios, and improves the low efficiency of traditional laser welding operations.

[0077] In one possible design, the welding torch is equipped with a multi-function button area, which includes a welding start button and a mode knob. Both the welding start button and the mode knob are connected to the host MCU via the welding torch MCU.

[0078] Specifically, an embedded mounting slot can be created in the gripping and operating area of ​​the welding torch. The welding start button is fixedly installed on one side of the mounting slot, and the multi-level mode knob is embedded on the other side of the mounting slot. The welding start button and the mode knob are directly connected to the pin interface of the welding torch MCU through built-in conductive ribbon cables. Then, the pin interface of the welding torch MCU is connected to the pin interface of the host MCU to realize the connection of the electrical circuit. This setting is used to centrally arrange the operation control components in the operating position of the welding torch body, realize the direct signal connection between the buttons and knobs and the host MCU, and facilitate the operator to directly complete the button triggering and level adjustment when holding the equipment.

[0079] The host MCU is also used to control the welding laser to switch from the stopped state to the ready-to-weld state in response to the welding start button being pressed.

[0080] Specifically, the host MCU can detect the level change of the welding start button in real time. When the button is pressed, a fixed level trigger signal is generated. After the host MCU recognizes the level trigger signal, it switches the state of the welding laser, allowing the welding laser to leave the shutdown state and enter the welding ready state. This setting is used to complete the switching and conduction of the working state of the welding laser after the button is manually triggered.

[0081] The welding torch MCU is also used to acquire the status of the mode knob and generate a mode signal based on the status; the mode signal is used to indicate the welding mode, which can be a graphic welding mode, a continuous welding mode, or a spot welding mode.

[0082] Specifically, the welding torch MCU can acquire the electrical code of the mode knob's position in real time. Different rotation positions correspond to different level combinations. After reading the corresponding level combination, the welding torch MCU matches the corresponding graphic welding mode, continuous welding mode, or spot welding mode and generates a mode signal with the corresponding encoding format. This setting is used to directly acquire the electrical state of the mode knob's position, match the corresponding welding type, and generate a dedicated signal. This signal is then transmitted to the host MCU through a serial communication interface, realizing the position correspondence and signal transmission of different welding modes between devices.

[0083] Optionally, the welding mode can include two input methods: one is direct input via the touchscreen, with the host MCU acquiring the mode signal; the other is input via a mode knob, with the welding torch MCU collecting the knob's state to generate a mode signal, which is then transmitted to the host MCU via communication. Regardless of the input method used, after determining the welding mode, the host MCU will transmit the mode along with other welding parameters back to the welding torch MCU to ensure synchronization between the welding torch and host sides.

[0084] The technical effect of this solution in this embodiment is as follows: By setting a multi-functional button area integrating a welding start button and a mode knob on the welding torch, the operator can conveniently switch working levels by rotating the mode knob. The welding machine MCU recognizes the knob status in real time and generates the corresponding mode signal, thereby completing the mode switching of graphic welding mode, continuous welding mode and spot welding mode. At the same time, the start signal can be triggered by pressing the welding start button to orderly control the laser to switch working states, realizing convenient triggering of welding operations, improving the convenience of welding mode switching and the smoothness of operation, and solving the technical problems of traditional welding equipment having a single operation mode, inconvenient mode switching, and difficulty in flexibly adapting to different welding processing conditions.

[0085] In one possible design, the control unit is also equipped with a preview laser, which is connected to the host MCU for communication. The preview laser is connected to the collimating lens via an optical fiber. The multi-function button area is also equipped with a two-stage trigger button, which is connected to the host MCU signal line.

[0086] Specifically, the preview laser can be fixedly installed in a reserved mounting position inside the control host. The preview laser and the host MCU pins are connected using an internal signal line. Then, an independent transmission optical fiber is used to connect the output end of the preview laser to the collimating lens. At the same time, a reserved mounting position is reserved in the multi-function button area of ​​the welding gun, and the two-stage trigger button is embedded in this position and connected to the corresponding interface of the host MCU via a signal line. This setting is used to add an independent preview light source and establish optical path connection at the control host. Meanwhile, a segmented trigger button is configured in the welding gun operation area to achieve stable electrical and optical path connection between the preview laser and the host MCU, and between the two-stage trigger button and the host MCU.

[0087] The host MCU is also used to respond to the first press of the two-stage trigger button, control the preview laser to transmit the preview laser to the collimating lens through the optical fiber based on the preset preview parameters. The collimating lens is used to collimate the preview laser to obtain the collimated preview laser, and then transmits the collimated preview laser to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated preview laser to obtain the focused preview laser.

[0088] Specifically, after the host MCU detects the first press of the two-stage trigger button, it retrieves the internally stored fixed preview parameters and outputs a matching drive level to the preview laser. The drive level is applied to the input of the preview laser's drive circuit, causing the preview laser to emit a low-power preview laser. This preview laser is transmitted through an optical fiber to a collimating lens, which focuses it into parallel light. The parallel light is reflected by the dual-mirror scanning module and enters the focusing lens, which focuses the beam into a small spot. At the same time, the welding torch MCU controls the dual-mirror scanning module to deflect the optical path, so that the focus of the preview laser scans visible lines along the welding path on the workpiece surface. This setting is used to clearly mark the trajectory outline to be welded on the workpiece surface with a low-power laser before the actual welding, allowing the operator to directly visually confirm whether the path position and the graphic are correct, thereby avoiding invalid welding or workpiece damage due to incorrect graphic selection or workpiece positioning deviation.

[0089] The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused preview laser to scan the welding path on the workpiece surface.

[0090] Specifically, the welding torch MCU can read the path point data sent by the host MCU and output different amplitude driving voltages to the two deflection motors of the dual galvanometer scanning module in sequence. This drives the two internal reflectors to change their deflection angles synchronously, continuously changing the propagation direction of the focused preview laser. This allows the focus of the focused preview laser to move sequentially along the path points, forming a continuous and visible line trajectory on the workpiece surface. This setting is used to change the laser output direction by successively changing the galvanometer angle, so that the focused preview laser presents a complete line trajectory on the workpiece surface, intuitively showing the position of the welding line to be processed.

[0091] The host MCU is also used to control the welding laser to transmit welding laser to the collimating lens based on welding parameters in response to the second press of the two-stage trigger button; wherein, the welding command refers to the second press of the two-stage trigger button, which is used to indicate that the welding path scanned on the workpiece surface is correct.

[0092] Specifically, a level signal recognition and processing unit can be installed inside the host MCU to configure two independent conduction circuits for the two-stage trigger button. The first press of the trigger triggers a low-level signal and leaves a signal mark. The host MCU stores the welding path data corresponding to the current preview laser. The second press of the trigger triggers a high-level trigger signal. After the host MCU recognizes the high and low level combination signal generated by the two presses, it retrieves the matched welding parameters and outputs a drive level signal to conduct the power supply transmission circuit of the welding laser. This controls the welding laser to stably output welding laser and transmit it to the collimating lens via optical fiber. This setting is used to lock the welding path that has been manually confirmed, control the start time of laser welding, distinguish the triggering actions of the preview optical path and the welding optical path, and avoid erroneous firing of the welding laser when the path has not been confirmed.

[0093] When the two-stage trigger button is pressed for the first time, the host MCU controls the preview laser to output a low-power laser, which marks the welding path on the workpiece surface through the galvanometer scanning module. After the operator confirms that the path is correct, pressing the trigger button a second time generates a welding command and starts the actual welding. This design presents the welding trajectory intuitively through a preview-confirmation process, avoiding rework due to path deviation. The first press of the two-stage trigger button generates a preview signal, and the second press must be completed within a limited time; otherwise, the system automatically cancels the preview path and returns to the initial state. This time limit prevents welding errors caused by misoperation.

[0094] The technical effect of this solution in this embodiment is as follows: By adding a preview laser to the control host and setting a two-stage trigger button in the multi-function button area, the host MCU can control the preview laser to emit light when the operator presses the trigger for the first time. After passing through the collimating lens, the dual galvanometer scanning module and the focusing lens, the outline of the preset welding path is scanned on the surface of the workpiece. After the operator visually confirms that the path position and the graphic are completely correct, the welding laser is officially started for welding only when the trigger is pressed a second time. This provides a zero-damage visual trajectory verification step before the formal welding, effectively avoiding invalid welding or workpiece scrap caused by workpiece positioning deviation, graphic selection error or abnormal path generation. It solves the technical problem in the existing laser welding system that the operator cannot visually confirm the weld trajectory before welding, and welding failure and workpiece damage are easily caused by position or graphic deviation.

[0095] In one possible design, the host MCU, when determining the welding mode as pattern welding mode based on the mode signal, specifically uses:

[0096] Obtain the welding pattern, the type of material required for welding, and the welding thickness.

[0097] Specifically, a graphics processing unit and a human-machine interface (HMI) can be added to the control host. The graphics processing unit and the HMI are connected to the host MCU via a parallel communication interface and a ribbon cable interface, respectively. The graphics processing unit directly converts manually drawn vector graphics or imported Drawing Interchange Format (DXF) files received by the HMI into control instructions adapted for the galvanometer. The HMI provides operation entry points for graphic drawing, parameter input, file retrieval, parameter package retrieval, and manual focusing. It internally stores welding process data corresponding to commonly used materials such as stainless steel, aluminum, copper, and titanium. After the host MCU recognizes the mode signal and determines that it is in graphic welding mode, it retrieves the selected welding graphic identifier from the HMI, reads the workpiece material category manually selected by the operator in the HMI, and simultaneously enters the workpiece thickness value set in the interface, completing the complete acquisition of three types of information. This setting is used to directly input and retrieve graphic, material type, and thickness information from the HMI, providing complete basic data support for subsequent comparison and matching with various preset parameter packages.

[0098] Optionally, the control host integrates a process database that stores preset parameter packages for welding parameters (laser power, pulse frequency, scanning speed) for different materials (such as stainless steel, aluminum, and copper). The host MCU, based on the user-input welding pattern, material type, and thickness, calls up the parameter packages in the process database and calculates the matching degree between the welding pattern, material type, and thickness and each parameter package using a matching algorithm. The parameters from the package with the highest matching degree are selected as the welding parameters. For example, when the user selects "304 stainless steel" and inputs a thickness of "1.2mm," the system automatically matches parameters such as laser power and frequency and generates a welding path with the specified scanning speed. This technical solution simplifies the operation process and improves the consistency of welding quality through intelligent parameter matching from the process database.

[0099] The system can dynamically adjust the radius of curvature of the welding path or the segmented welding sequence by real-time detection of material deformation data (such as heat-affected zone expansion and localized heat accumulation) and laser power feedback data during the welding process, combined with historical welding data from the process database. For example, when localized heat accumulation causing material deformation is detected, the system automatically increases the radius of curvature of the scanning path to reduce the heat input density, or adjusts the segmented welding sequence to prioritize welding heat-sensitive areas. This algorithm optimizes the path through closed-loop control, ultimately achieving a dynamic balance of thermal stress distribution during the welding process, avoiding material deformation or weld cracking caused by localized overheating, and significantly improving the consistency of welding quality.

[0100] The matching degree between the welding pattern, the type of material required for welding, and the welding thickness and multiple preset parameter packages is calculated, and the parameters in the preset parameter package corresponding to the maximum matching degree are determined as welding parameters; among them, the welding parameters include initial laser power, initial pulse frequency, initial duty cycle and initial scanning speed.

[0101] Specifically, the welding pattern, the type of material required for welding, and the welding thickness can be compared item by item with the corresponding pattern adaptation type, adaptation material category, and adaptation thickness range in each set of preset parameter packages. The scores of these three matching items are calculated and accumulated to obtain the corresponding score of each set of parameter packages. The set of preset parameter packages with the highest accumulated score is selected, and the initial laser power, initial pulse frequency, initial duty cycle, and initial scanning speed in that set are directly extracted as the welding parameters to be used. This setting is used to compare each preset parameter package according to multiple features, select the parameter group with the highest adaptation degree, and directly use the corresponding process parameters for welding operations.

[0102] In graphic welding mode, the host MCU acquires the welding pattern, material type, and thickness through the graphics processing unit and calculates the matching degree with multiple pre-stored preset parameter packages. The host MCU compares the contour features, material type (such as stainless steel, aluminum, and copper), and thickness (such as 1.0mm and 1.5mm) of the welding pattern with the matching conditions in the parameter packages, calculates the matching degree score, and selects the parameters such as laser power and pulse frequency from the parameter package with the highest score as the welding parameters to ensure the consistency of welding quality under different materials and thicknesses.

[0103] Optionally, a high-precision timer can be configured inside the host MCU. This timer starts when the laser beam is emitted and stops when welding ends, thus obtaining the total welding time. Simultaneously, the host MCU continuously collects the real-time output power and pulse frequency of the laser during welding. It integrates and accumulates the energy (power × pulse width) of each pulse with the number of pulses, or directly reads the energy monitoring value fed back by the laser, to calculate the total energy consumed in this welding operation. After calculation, the host MCU sends the welding time and energy consumption data to the human-machine interface (HMI) via a serial communication interface (such as RS485, CAN, or Ethernet). The HMI then uses preset display controls to present the welding time and energy consumption to the operator in real-time, displaying the numerical values ​​and units (seconds, joules, or kilowatt-hours).

[0104] The technical effect of this solution in this embodiment is as follows: the host MCU automatically acquires the welding pattern, material type and thickness in the graphic welding mode, and calculates the matching degree with multiple preset parameter packages. The initial laser power, pulse frequency, duty cycle and scanning speed in the parameter package with the highest matching degree are determined as the welding parameters, realizing the automated matching of welding parameters. Operators do not need to have professional process knowledge to obtain the basic parameter configuration suitable for the current welding task, which reduces the threshold of parameter setting and trial and error costs. It solves the technical problem in the prior art that the setting of laser welding parameters depends on the operator's experience and manual adjustment, which leads to cumbersome setting, easy error and high requirements for personnel skills.

[0105] In one possible design, the welding torch MCU is used to acquire the real-time welding speed and send the real-time welding speed to the host MCU.

[0106] Specifically, the frequency of angle changes and the amount of angle displacement of the deflection mirror inside the dual galvanometer scanning module can be collected in real time. The moving rate of the laser focus on the workpiece surface can be calculated as the real-time welding speed. The rate value is then continuously transmitted to the host MCU through the internal communication link of the equipment. This setting is used to calculate the speed of the spot movement from the galvanometer deflection action and transmit the real-time rate data to the host MCU to provide a rate basis for the adaptation and adjustment of laser energy.

[0107] The host MCU is also used to acquire real-time laser power and real-time pulse frequency, and adjust the real-time laser power and real-time pulse frequency according to the real-time welding speed to keep the laser energy per unit length of weld constant.

[0108] Specifically, the host MCU can read the current laser power and pulse frequency values ​​of the laser's output port in real time through a power monitoring sensor set in the laser's output optical path. The power monitoring sensor is electrically connected to the analog signal acquisition terminal of the host MCU. After receiving the real-time welding speed transmitted by the welding torch MCU, the host MCU adjusts the laser power output level and pulse frequency level accordingly based on the speed. When the welding speed increases, the laser power and pulse frequency are increased synchronously, and when the welding speed decreases, the laser power and pulse frequency are decreased synchronously, keeping the laser energy received per unit length of weld consistent. This setting is used to synchronously adjust the laser output power and pulse frequency according to the speed of the laser spot movement, maintaining a balanced and uniform laser energy received per unit length of weld.

[0109] The technical effect of this solution in this embodiment is as follows: the actual scanning speed during the welding process is obtained in real time by the welding torch MCU and reported to the host MCU. At the same time, the host MCU monitors the real-time output power and pulse frequency of the laser and adjusts the power and frequency synchronously according to the dynamic changes in speed, so that the laser energy output and the focus movement speed are matched in real time. This ensures that the energy obtained per unit length of the weld remains constant, suppresses local overmelting or incomplete melting defects caused by acceleration or deceleration at graphic corners or slight hand movements, improves the uniformity and consistency of the weld, and solves the technical problem of unstable weld energy and poor welding quality consistency caused by scanning speed fluctuations in existing handheld graphic welding systems.

[0110] In one possible design, the welding torch MCU is also used to acquire the real-time attitude of the welding torch during the welding process and the initial attitude of the welding torch before welding begins, and send the real-time attitude and the initial attitude to the host MCU.

[0111] Specifically, an attitude sensing device can be installed inside the welding torch and directly connected to the pins of the welding torch MCU. When the welding torch is stationary and not in operation, the welding torch MCU collects the original orientation data of the sensing device as the initial attitude. During the welding operation, the real-time orientation data of the sensing device is continuously collected as the real-time attitude. Then, the original data of the initial attitude and the real-time attitude are synchronously transmitted to the host MCU through the internal communication bus. This setting is used to collect the reference orientation of the welding torch when it is stationary and the real-time orientation data during the operation, providing original data support for subsequent comparison and calculation of attitude offset.

[0112] The host MCU is also used to calculate the welding torch attitude offset based on the real-time attitude and the initial attitude. If the welding torch attitude offset is greater than or equal to the preset offset threshold, the welding path is corrected according to the welding torch attitude offset to obtain the corrected welding path, and the corrected welding path is sent to the welding torch MCU.

[0113] Specifically, the initial attitude includes the reference angle parameters of the welding torch in the pitch, roll, and yaw axes when welding has not started. The real-time attitude includes the real-time angle parameters of the welding torch in the pitch, roll, and yaw axes during welding. The host MCU can receive the initial attitude three-axis angle parameters and the real-time attitude three-axis angle parameters transmitted by the welding torch MCU, calculate the angle difference in the pitch, roll, and yaw axes respectively, integrate the differences in each axis to obtain the overall spatial angle difference as the welding torch attitude offset, retrieve a preset fixed angle value as the offset threshold, and compare the calculated attitude offset with this threshold. Yes, when the attitude offset does not exceed the threshold limit, the horizontal and vertical coordinates of each coordinate point of the original welding path are compensated according to the offset angle of each axis. The spatial position of the path points is finely adjusted point by point to generate a complete corrected welding path coordinate sequence that adapts to the current welding torch tilt angle. Then, the entire set of corrected path coordinate sequences is sent to the welding torch MCU frame by frame through the communication interface. This setting is used to obtain the overall attitude offset by synthesizing the multi-axial angle difference. When the offset is within the allowable range, the coordinates of the original welding path points are compensated point by point to generate new path data that adapts to the welding torch placement angle and completes the transmission.

[0114] The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focus of the focused welding laser is welded on the workpiece surface according to the corrected welding path.

[0115] Specifically, after receiving the coordinate data of each point on the corrected welding path from the host MCU, the welding torch MCU can output the corresponding driving voltage to the X-axis and Y-axis galvanometer drive units in the dual galvanometer scanning module in sequence according to the timing. This causes the two galvanometer lenses to rotate synchronously, continuously changing the focused welding laser propagation path. This allows the laser focus to move sequentially along the coordinate points of the corrected welding path and stably stop at the corresponding position on the workpiece to complete the fusion. This setting is used to accurately control the galvanometer deflection angle based on the corrected path coordinates, guide the welding laser focus along the corrected trajectory, adapt to the routing requirements after a slight shift in the welding torch posture, and ensure that the welding trajectory on the workpiece surface conforms to the preset contour.

[0116] Optionally, the host MCU calculates the offsets in the pitch, roll, and yaw axes by comparing the real-time attitude during the welding process with the initial attitude. When the offset is less than a preset threshold and the laser focus offset is less than the welding pattern tolerance range, lateral and longitudinal compensation is performed on each coordinate point of the welding path according to the axial offset angle to generate a corrected path. This setting limits the correction range through tolerance range to avoid trajectory distortion caused by over-correction.

[0117] The host MCU calculates the welding torch attitude offset based on the real-time and initial attitudes. If the offset is less than or equal to a preset offset threshold, the welding path is corrected. If the offset is greater than the threshold but no other alarm conditions are triggered, the host MCU prioritizes path correction and reduces laser power. If the offset is greater than the threshold and other alarm conditions are triggered (such as excessive temperature), the host MCU prioritizes reducing laser power and sending an alarm signal, without further path correction. This design ensures both welding accuracy and equipment safety under different offset levels through tiered processing.

[0118] The technical effect of this solution in this embodiment is as follows: the welding torch MCU collects the welding torch posture during the welding process and the initial posture before welding begins in real time, and the host MCU calculates the posture offset. When the offset is within the compensable range, the original welding path is actively corrected in real time to generate a corrected path. Then, the welding torch MCU controls the dual galvanometer scanning module to deflect the optical path according to the corrected path. This dynamically cancels the focus position deviation caused by hand shaking or posture changes during handheld operation, so that the actual laser scanning trajectory always maintains a precise match with the preset pattern. This improves the trajectory accuracy and welding quality of handheld pattern welding, and solves the technical problem that existing handheld laser welding equipment lacks a shaking compensation mechanism, which leads to welding pattern offset, deformation, and inability to guarantee accuracy due to operator hand instability during handheld operation.

[0119] In one possible design, the laser welding system further includes a rectifier power supply, a first step-down circuit, a second step-down circuit, and a third step-down circuit. The AC power supply and the welding laser are both electrically connected to the rectifier power supply. The AC power supply and the second step-down circuit are both electrically connected to the first step-down circuit. The second step-down circuit is electrically connected to the host MCU. The first step-down circuit and the welding torch MCU are both electrically connected to the third step-down circuit.

[0120] The first step-down circuit is an AC-DC converter that converts AC power into medium-voltage DC power. The second and third step-down circuits are DC-DC converters that further step down the medium-voltage DC power into low-voltage DC power. The second step-down circuit is used to provide operating power to the host MCU, and the third step-down circuit is used to provide operating power to the welding torch MCU.

[0121] Specifically, the AC power supply can output 220V AC power, which can be simultaneously connected to both the rectifier power supply and the first step-down circuit. The rectifier power supply rectifies the 220V to 50V DC to supply the welding laser as its main power source. The first step-down circuit steps the 220V to 24V DC. One path of this 24V is stepped down to 3.3V by the second step-down circuit to power the main MCU, and the other path is stepped down to 3.3V by the third step-down circuit to power the welding torch MCU. This setup is used to electrically isolate the high-voltage power circuit of the welding laser from the low-voltage control circuits of the main MCU and the welding torch MCU. It also provides independent and stable low-voltage DC power to both MCUs, preventing interference with the control signals during laser startup or fluctuations, and ensuring that the entire system can operate stably and reliably under different power supply requirements.

[0122] The welding torch MCU is also used to obtain the first fluctuation amplitude of the welding torch temperature and the output power of the rectifier power supply, and send the first fluctuation amplitude to the host MCU.

[0123] Specifically, an NTC thermistor or digital temperature sensor can be mounted inside the welding torch and connected to the welding torch MCU via an ADC interface or a single bus. Simultaneously, the output of the rectified power supply is connected to another ADC pin of the welding torch MCU via a resistor divider or Hall effect voltage sensor. The welding torch MCU continuously samples voltage values ​​at a fixed sampling rate and calculates the absolute value of the difference between adjacent sampling points. This difference is used as the first fluctuation amplitude and, along with the temperature value, is sent to the host MCU via a communication cable. This setup allows the host MCU to monitor the output stability of the rectified power supply and whether the welding torch is overheating in real time. This allows for timely interruption of the welding laser or reduction of power in case of excessive power fluctuations or abnormal welding torch temperature, preventing degradation of weld quality or equipment damage.

[0124] The welding torch MCU is also used to send a first alarm signal to the host MCU when the welding torch attitude offset is greater than a preset offset threshold or the temperature is greater than a preset temperature threshold.

[0125] Specifically, a six-axis inertial measurement unit (IMU) can be integrated inside the welding torch to acquire real-time attitude data. The welding torch MCU reads the data from this IMU and compares it with the initial attitude recorded upon power-up, calculating the difference between the pitch and yaw angles as the attitude offset. Simultaneously, a thermistor is mounted inside the welding torch to measure the temperature. When the attitude offset exceeds an internally stored offset threshold or the temperature exceeds an internally stored temperature threshold, the welding torch MCU outputs a high-level signal via a dedicated signal line or sends a specific format alarm frame via serial port as the first alarm signal to the host MCU. This setup immediately notifies the host MCU when the welding torch holding angle deviation is too large or the welding torch overheats, allowing the host MCU to promptly stop the welding laser output or trigger an audible and visual alarm, preventing weld seam misalignment due to incorrect operating angles or damage to the internal optical components of the welding torch due to overheating.

[0126] The host MCU is also used to obtain the second fluctuation amplitude of the real-time laser power, and generate a second alarm signal when the first fluctuation amplitude is greater than a preset first amplitude threshold or the second fluctuation amplitude is greater than a preset second amplitude threshold.

[0127] The first fluctuation amplitude refers to the change in the output power of the rectifier power supply per unit time, obtained by continuously sampling the rectified voltage and calculating the absolute value of the difference between adjacent sampling points. The second fluctuation amplitude refers to the change in the real-time laser power of the welding laser per unit time, obtained by continuously acquiring the laser power signal with a photodetector and calculating the absolute value of the difference between adjacent sampling points. A preset first amplitude threshold is a pre-defined value used to measure the maximum allowable change in the output power of the rectifier power supply; an alarm is triggered when the actual fluctuation amplitude exceeds this value. A preset second amplitude threshold is also a pre-defined value used to measure the maximum allowable change in the real-time laser power of the welding laser; an alarm is triggered when the actual fluctuation amplitude exceeds this value.

[0128] Specifically, a beam splitter can be placed in the output optical path of the welding laser to split a small portion of the laser beam onto a photodetector. The photodetector converts the light intensity into a voltage signal and sends it to the ADC pin of the host MCU. The host MCU continuously samples this voltage value at a fixed period, calculates the absolute value of the difference between two adjacent sample values ​​as the second fluctuation amplitude, and compares the received first fluctuation amplitude with the internally stored first amplitude threshold and the second fluctuation amplitude with the internally stored second amplitude threshold. If any exceeds the threshold, a high-level output is generated or an alarm code is sent via the bus as a second alarm signal. This setup allows the host MCU to actively issue a second alarm signal when the rectified power supply output is unstable or the laser's own power fluctuation exceeds the allowable range, so that external protection circuits or operators can immediately interrupt the welding process, ensuring the consistency of weld energy.

[0129] The host MCU is also used to trigger preset protection measures corresponding to the alarm type based on the alarm type of the first alarm signal and the second alarm signal.

[0130] Specifically, a protection action table corresponding to alarm signal feature codes can be established internally by the host MCU. When the first alarm signal is received, the host MCU controls the solid-state relay connected in series at the output of the rectifier power supply to disconnect via the I / O port, directly cutting off the power supply to the welding laser. When the second alarm signal is received, the host MCU outputs a low level to the enable terminal of the welding laser via the DAC, forcibly reducing the laser output power to zero. This setting is used to execute different hardware-level protection operations for different fault sources. For example, a complete power cut-off is performed when the welding torch posture is abnormal or overheating occurs, while only the laser output is shut down but the control circuit is kept powered when the power supply or laser power fluctuates, enabling the equipment to take appropriate protection actions according to the severity of the fault.

[0131] The technical effect of this solution in this embodiment is as follows: A rectified power supply and a three-stage step-down circuit provide suitable power to the welding laser, the host MCU, and the welding torch MCU respectively. Simultaneously, the welding torch MCU collects the welding torch temperature and the output power fluctuations of the rectified power supply, while the host MCU collects the laser power fluctuations. When the welding torch posture deviation is too large, the temperature is too high, the power supply fluctuation is too large, or the laser power fluctuation is too large, corresponding alarm signals are generated, and corresponding protection actions are executed for different alarm types. This achieves comprehensive detection and graded protection of power supply stability, welding torch status, and laser output quality, effectively preventing equipment damage due to abnormal conditions.

[0132] In one possible design, the laser welding system also includes a fourth step-down circuit. The dual galvanometer scanning module includes a galvanometer motor. The galvanometer motor and the first step-down circuit are both electrically connected to the fourth step-down circuit. The welding torch is equipped with a welding torch housing and a welding torch air duct. The control host is equipped with a host housing, a host air duct, and a fan. The fan is electrically connected to the host MCU. The host MCU is used to output a PWM speed control signal to the fan to adjust the fan speed.

[0133] Specifically, a fourth step-down circuit can be connected in parallel to the 24V DC bus output from the first step-down circuit. This fourth step-down circuit uses an LM2596 step-down DC-DC converter to reduce the 24V to 15V, directly powering the galvanometer motor. Simultaneously, a first air inlet and outlet are created on the welding torch housing to form a welding torch air duct, allowing external air to flow through the galvanometer motor and lens housing, carrying away heat. A second air inlet and outlet are created on the main unit housing to form a main unit air duct, with a fan installed inside. The main unit MCU adjusts the fan speed in real time by outputting PWM square wave signals with different duty cycles to the fan speed control pin. This setup provides an independent and stable low-voltage power supply to the galvanometer motor and utilizes the air duct to guide airflow to cool the optomechanical components inside the welding torch and the welding laser inside the main unit. Furthermore, PWM speed control adjusts the fan speed to accommodate different heat levels, preventing overheating that could cause the galvanometer motor to lose synchronization or the laser output to attenuate.

[0134] Optionally, sealing and limiting installations can be made on the alignment lens and focusing lens to prevent external dust or moisture from entering the lens surface and affecting the quality of optical path transmission. At the same time, a hollow channel is reserved inside the welding torch housing to form an integrated welding torch air duct. This setting is used to provide an independent airflow channel for subsequent air cooling while ensuring the sealing of the optical lens.

[0135] The first air inlet and the first air outlet of the welding torch air duct are both located on the welding torch housing. External air enters the welding torch air duct from the first air inlet, flows through the sealed housing of the galvanometer motor, collimating lens and focusing lens, and then exits the welding torch air duct from the first air outlet.

[0136] Specifically, a perforated hole can be made on the side wall of the welding torch housing as the first air inlet, and a corresponding perforated hole can be made at the tail of the welding torch housing as the first air outlet. The welding torch air duct is arranged in a through channel along the internal space of the housing. Outside ambient temperature air flows into the welding torch air duct through the first air inlet and flows sequentially through the sealed housing of the galvanometer motor, the sealed housing of the collimating lens, and the sealed housing of the focusing lens. Heat exchange is achieved through the heat dissipation fins or micropores on the surface of the housing. The heat accumulated in the three sealed housings is carried out and discharged outward from the first air outlet. This can continuously dissipate heat from the sealed housings of the galvanometer motor, the collimating lens, and the focusing lens, adapting to the ventilation and heat dissipation requirements of the narrow internal space of the welding torch and avoiding the problem of fluctuation in the working state of the device caused by heat retention in the closed space.

[0137] Both the galvanometer motor and the optical lens are encapsulated in a sealed housing. Airflow only exchanges heat through the outer wall of the sealed housing, preventing external dust or moisture from directly contacting the lens surface or the inside of the motor, thereby preventing a decline in optical performance or motor positioning drift.

[0138] The second air inlet and the second air outlet of the host air duct are both located on the host housing. The fan is located inside the host air duct. The fan is used to draw in external air and deliver the external air to the welding laser through the airflow generated by the fan rotation. The external air is used to absorb the heat of the welding laser and then discharged from the host air duct through the second air outlet.

[0139] Specifically, a grille-style opening can be made on the side of the main unit housing as a second air inlet, and a corresponding exhaust opening can be made on the back of the main unit housing as a second air outlet. The fan is fixedly installed on the inner side of the main unit air duct near the second air inlet. When the fan is running, outside air is introduced from the second air inlet, and the airflow is guided to flow directionally along the main unit air duct to the surface of the welding laser housing. After the air contacts the laser housing, it carries away the accumulated heat, and then is discharged out of the main unit housing from the second air outlet along the air duct passage. This setting is used to rely on the fan to actively guide the airflow to form a directional airflow, continuously carrying away the surface heat accumulated by the welding laser and keeping the welding laser in a suitable operating temperature range.

[0140] Optionally, a safety interlock button and an emergency stop button can also be installed on the control host. Both are connected to the general-purpose input / output pins of the host MCU through independent digital input interfaces. The safety interlock button uses a dual-circuit redundant wiring method to ensure that the protection signal can still be reliably triggered if any circuit fails. The emergency stop button is preferentially connected to the hardware-level interrupt port and connected in series to the control coil circuit of the main power contactor. The safety interlock button is used to detect the critical protection status of the equipment, such as whether the protective door is closed and whether the laser protective cover is in place. Only when the button is triggered and the status is normal will the host MCU allow laser output and galvanometer operation. Once the interlock condition fails, the MCU immediately cuts off the laser output and suspends the welding process. The emergency stop button, as the highest priority protection device, directly disconnects the main power contactor when pressed, causing the entire system, including the laser, galvanometer, wire feeding mechanism, etc., to immediately stop all movement and energy output. At the same time, it sends an interrupt signal to the MCU to record fault information, thereby ensuring the safety of operators and equipment in emergency situations.

[0141] The dual-mirror scanning module also includes a motor drive module, which is connected to the welding torch MCU. The motor drive module is used to control the X-axis galvanometer motor and the Y-axis galvanometer motor in the dual-mirror scanning module. The welding torch MCU sends position commands to the motor drive module, which converts the commands into drive current, so that the two motors drive the reflector mirrors to deflect, thus moving the welding laser focus together.

[0142] The technical effect of this solution in this embodiment is as follows: By setting an independent welding torch air duct on the welding torch housing, external air is discharged after passing through the sealed shells of the galvanometer motor, collimating lens, and focusing lens. This achieves directional air cooling for key moving and optical components inside the welding torch, preventing galvanometer motor positioning drift and heat contamination or deformation of optical lenses due to temperature rise. At the same time, a host air duct and fan are set inside the control host to force external air into the welding laser and discharge it, providing active air cooling for the laser. This low-cost air cooling solution replaces the traditional bulky and expensive water cooling system, ensuring the thermal stability and reliability of the dual galvanometer module and laser during long-term continuous operation. It solves the technical problem in existing handheld graphic laser welding systems where the high heat dissipation requirements are due to the integration of the dual galvanometer scanning module inside the handheld welding torch and the laser inside the control host, while traditional water cooling solutions are costly and bulky, and simple passive cooling cannot meet thermal management requirements, thus affecting welding accuracy and equipment lifespan.

[0143] In one possible design, the welding laser is equipped with a temperature sensor, which is electrically connected to the host MCU. The temperature sensor is used to collect the temperature signal of the welding laser, convert the temperature signal into an analog voltage, and send the analog voltage to the host MCU. The host MCU is used to convert the analog voltage into temperature and adjust the fan speed according to the temperature.

[0144] Specifically, an NTC thermistor can be used as the temperature sensor. The thermistor is fixed tightly against the outer shell of the welding laser. One end of the thermistor is connected to the 3.3V reference voltage output of the host MCU, and the other end is connected to ground via a 10kΩ precision resistor in series. A signal line is led out from the series junction and directly connected to the analog input pin of the host MCU. When the temperature of the welding laser changes, the resistance of the thermistor changes, causing a change in the voltage division value at the series junction. This voltage division value is sent as an analog voltage to the analog-to-digital converter of the host MCU. The host MCU internally stores a voltage-temperature lookup table. By looking up the table, the current analog voltage is converted into the actual temperature. Then, based on the actual temperature, different duty cycles of PWM signals are output to control the fan speed; the higher the temperature, the larger the PWM duty cycle, and the faster the fan rotates. This setup converts the temperature changes of the welding laser into a processable voltage signal in real time, allowing the host MCU to dynamically adjust the cooling intensity of the fan based on accurate temperature readings, ensuring that the welding laser is always within a suitable operating temperature range.

[0145] An active fan is installed in the welding torch air duct. The fan is electrically connected to the host MCU and is used to output a PWM speed control signal to the fan. When the laser temperature rises, the fan automatically speeds up and accelerates heat dissipation through forced airflow, thus preventing the laser from becoming unstable in power or the optical lens from fogging due to temperature rise.

[0146] When the temperature sensor detects that the welding laser temperature exceeds a preset threshold, the host MCU prioritizes triggering power reduction logic and sending an alarm signal, while simultaneously adjusting the fan speed according to the temperature range. This setting, through hierarchical priority protection, ensures that laser power is reduced first in case of abnormal temperature to avoid equipment damage.

[0147] The technical effect of this solution in this embodiment is as follows: by setting a temperature sensor on the welding laser to determine the laser temperature in real time, and the host MCU dynamically adjusts the fan speed according to the temperature, the fan runs at a low speed when the laser is low to reduce energy consumption and noise, and automatically speeds up when the laser is high to enhance heat dissipation. This achieves intelligent air cooling on demand, avoids the energy waste and noise pollution caused by traditional fixed-speed fans working at full speed for a long time, ensures the thermal stability and equipment lifespan of long-term continuous welding operations, and solves the technical problems of high energy consumption, high noise, and rapid lifespan loss caused by constant high-speed operation of fans in existing low-cost laser welding systems, or untimely heat dissipation and frequent triggering of laser overheat protection due to the lack of temperature feedback closed-loop control.

[0148] In one possible design, the welding torch MCU is also used to send a welding completion signal to the host MCU in response to the focus of the focused welding laser having traversed the welding path.

[0149] Specifically, the welding torch MCU can record all the coordinate points of the dual galvanometer scanning module as it completes the corrected welding path. After the last coordinate point is completed and the laser focus has completed the entire welding path, a welding completion command in the form of a fixed level is generated and transmitted directly to the host MCU via the inter-board communication line. This setting is used to promptly transmit the end command to the host MCU after the laser focus has completed the entire predetermined welding path, providing a trigger basis for shutting down the welding laser.

[0150] The host MCU is also used to control the welding laser to stop running in response to the welding completion signal.

[0151] Specifically, after receiving the welding completion signal from the welding torch MCU, the host MCU can immediately output a shutdown level to the enable control terminal of the welding laser, cut off the laser's working enable path, terminate the laser's laser emission state, and keep the laser in a static standby state. This setting is used to receive the completion signal after the path is completed and directly send a shutdown control level to cut off the laser's working state, so as to realize the timely shutdown of the laser after the welding operation is completed.

[0152] The welding torch MCU records the coordinates of all points along the welding path sequentially by the dual-mirror scanning module. Once the last point is completed, a welding completion signal is generated and sent to the host MCU. Upon receiving the signal, the host MCU immediately shuts off the laser output. The status indicator module uses different light colors (such as green for power-on, yellow for standby, red for alarm, and blue for completion) to visually indicate the equipment status, allowing the operator to monitor the welding process without checking the screen and reducing errors.

[0153] The technical effect of this solution in this embodiment is as follows: After the welding torch MCU detects that the laser focus has completed the entire traversal of the welding path, it automatically sends a welding completion signal to the host MCU, and the host MCU immediately controls the welding laser to stop running. This realizes the automatic termination of the welding process and the laser shutdown, eliminating the need for the operator to manually judge the welding end time or press the stop button. This avoids workpiece damage caused by over-welding, energy waste caused by laser dry burning, and safety hazards caused by the operator forgetting to turn off the laser. It improves the automation and safety of the welding process and solves the technical problem of existing handheld laser welding systems requiring manual laser shutdown after graphic welding, which is prone to workpiece over-burning due to response delay or operational negligence.

[0154] In one possible design, the welding torch is equipped with a status indicator module, which is connected to the welding torch MCU signal line. The welding torch MCU is also used for:

[0155] In response to the start of AC power supply to the first step-down circuit, the control status indicator module outputs a power-on light prompt.

[0156] Specifically, a resistor divider network can be connected in series between the 24V output of the first step-down circuit and ground. The divider point is then connected to an I / O port with interrupt functionality of the welding torch MCU. When the AC power supply starts and the 24V voltage rises from zero to the threshold, this I / O port generates a rising edge interrupt. Upon detecting the interrupt, the welding torch MCU immediately outputs a high level through another I / O port to drive a green LED to light up for 0.5 seconds and then turn off, serving as a power-on indicator. This setup provides clear and immediate visual feedback to the operator, indicating that the system is connected to AC power and the first step-down circuit is working properly, preventing operators from misoperating or repeatedly checking the power supply when it is not powered on.

[0157] In response to the welding laser switching from the shutdown state to the welding standby state, the control status indicator module outputs a standby status light prompt.

[0158] Specifically, the welding torch MCU can detect the laser standby level signal sent by the host MCU. When it recognizes that the welding laser has left the stop position and entered the welding position, it outputs an intermittent on / off level to the corresponding light-emitting device inside the status indicator module, so that the light-emitting device lights up alternately at fixed intervals. This setting is used to intuitively indicate the standby position of the equipment with a special light pattern when the laser enters a position that can be started at any time.

[0159] In response to the first alarm signal or the second alarm signal, the control status indicator module outputs a fault alarm light prompt.

[0160] Specifically, a red LED can be connected to a GPIO port of the host MCU. When the host MCU receives a first or second alarm signal through its internal logic, the GPIO port outputs a square wave signal with a frequency of 1Hz and a duty cycle of 50%, driving the red LED to flash continuously at a frequency of once per second. This setting is used to provide a clear visual warning to on-site operators, indicating that any of the following—welding torch posture, welding torch temperature, power supply fluctuation, or laser power fluctuation—has exceeded the allowable range, requiring immediate cessation of work and inspection of the equipment status.

[0161] In response to the welding completion signal, the control status indicator module outputs a light prompt indicating that the job is complete.

[0162] Specifically, after the welding torch MCU recognizes that the welding completion signal it generates has been effectively triggered, it outputs a constant light-emitting drive level to the designated light-emitting device of the status indicator module, switching to a unique light color that is different from power-on, standby, and alarm light. This setting is used to give a clear indication with a unique constant light pattern after a single welding operation has completed its full path, so that people can intuitively know that the current welding process has been completed.

[0163] The status indicator module on the welding torch uses different light states to indicate the equipment's operating stage. Optionally, a solid green light illuminates when powered on, a flashing yellow light appears during standby, a high-frequency flashing red light indicates an alarm, and a solid blue light illuminates when welding is complete. Operators do not need to check the main unit screen; they can intuitively understand the equipment status simply by observing the lights at the tail of the welding torch, reducing the risk of misoperation.

[0164] The technical effect of this solution in this embodiment is as follows: By setting a status indicator module connected to the welding torch MCU signal line on the welding torch, and having the welding torch MCU respond to power-on, standby, fault alarm, and welding completion signals respectively, the status indicator module automatically outputs power-on light prompts, standby light prompts, fault alarm light prompts, and job completion light prompts. This allows the operator to intuitively and in real-time grasp the key status of the system, such as power-on, standby, alarm, or welding completion, without having to look away from the control host screen, simply by observing the light changes at the tail of the welding torch. This effectively avoids safety hazards such as misoperation due to unclear status, inadequate readiness before startup, failure to detect faults in time, or failure to turn off the light in time after welding. It also solves the technical problem in existing handheld laser welding systems where operators need to frequently check the host interface or rely on auditory signals to obtain the equipment status, easily overlooking status changes and leading to operational errors.

[0165] Optionally, an 8-core cable can be used to connect the welding torch to the control host. Two cores transmit 24V power and ground to the welding torch power supply module; two cores serve as a 485 communication bus connecting the welding torch MCU and the host MCU for bidirectional data exchange; one core transmits the welding torch trigger signal to the host laser control I / O for controlling the laser output switch; one core feeds back the welding torch temperature or fault signal to the host alarm input; one core connects the welding torch housing grounding detection and the host safety circuit to form a loop continuity line; and finally, one core sends the welding completion status signal from the welding torch MCU to the host MCU. By using a single 8-core cable to connect the welding torch to the control host, the 485 bus is used for bidirectional communication such as graphic path and status data, while hardwiring is used for safety signals with extremely high real-time requirements, such as laser switching, alarms, and loop continuity. This approach balances data transmission bandwidth and safety response speed, avoids the delays of pure bus communication in emergency situations, and reduces wiring complexity and cost.

[0166] This application also provides a workpiece welding processing system, including: a workpiece and a laser welding system, wherein the laser welding system is used to perform welding on the workpiece.

[0167] Specifically, the workpiece to be processed can be placed directly on the working plane, and the laser welding system can be set up in the working area next to the workpiece. The laser emission end of the welding gun is aligned with the joint to be welded on the workpiece. Relying on the laser welding system's own optical path deflection, power control, air duct heat dissipation and status indication structure working together, after the welding path preview is correct, the welding laser is directly output to the workpiece to be processed position to complete the fusion. This setup is used to combine the workpiece and the laser welding system into an integrated processing assembly, and rely on the complete configuration of the laser welding system to directly complete the laser welding operation on the workpiece to be processed area.

[0168] The workpiece welding processing system is portable in design with welding torch and control host, making it suitable for various scenarios such as batch processing in the workshop, on-site repair and welding of irregular patterns. Operators can directly hold the equipment and work next to the workpiece without having to carry the workpiece to a fixed processing center, which shortens the auxiliary preparation time. At the same time, it can realize complex pattern welding through dual galvanometer scanning module, meeting diverse needs such as precision device packaging and steel structure docking.

[0169] The technical effect of this solution in this embodiment is as follows: By combining the workpiece with the laser welding system, and utilizing the dual galvanometer scanning module integrated inside the handheld welding torch in the system, as well as the coordinated control of the host MCU and the welding torch MCU, the operator can directly perform one-time precise welding of complex shapes on-site. There is no need to transport the workpiece to a fixed processing center, nor is there a need to rely on manual dragging to form the weld. This shortens the flow time of the workpiece from the processing position to the welding station and the auxiliary preparation time, ensures the accuracy and consistency of the welding trajectory, improves the processing efficiency and finished product quality of the workpiece, and reduces the investment in large equipment and site occupation costs. It solves the technical problems of low efficiency and high cost caused by the need to transport the workpiece to a large fixed shape welding equipment before complex shape welding can be performed, or the inability of traditional handheld devices to perform complex shape welding on workpieces.

[0170] Figure 1 This is a schematic flowchart of the laser welding method provided in the embodiments of this application, as shown below. Figure 1 As shown, laser welding methods include:

[0171] S101. Obtain the mode signal. If the welding mode is determined to be graphic welding mode based on the mode signal, then obtain the welding graphic and welding parameters, generate the welding path according to the welding graphic, and send the welding path to the welding gun MCU. The welding gun MCU and the welding laser are both connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber. The dual galvanometer scanning module is connected to the welding gun MCU.

[0172] Specifically, the host MCU can receive mode signals through the inter-board communication interface, identify the corresponding gear indicator to determine that it has entered the graphic welding mode, retrieve the welding graphic data of the corresponding contour shape and the matching welding parameters such as current and time stored locally, fit the continuous coordinate points to form the welding path according to the contour nodes of the welding graphic, and then transmit the coordinate data of the entire welding path to the welding gun MCU in groups according to a fixed communication frame format. This step is used to receive the gear signal sent by the welding gun side and identify the corresponding working mode, retrieve the matching graphic and parameter data to fit and generate path coordinates, and then send the formed path data to the welding gun MCU to provide coordinate basis for subsequent optical path deflection operations.

[0173] S102. In response to the welding command, the welding laser is controlled to transmit the welding laser through an optical fiber to a collimating lens based on the welding parameters. The collimating lens is used to collimate the welding laser to obtain a collimated welding laser. The collimated welding laser is then transmitted to a focusing lens through a dual-mirror scanning module. The focusing lens is used to focus the collimated welding laser to obtain a focused welding laser. The welding torch MCU is used to control the dual-mirror scanning module to deflect the optical path of the focused welding laser so that the focal point of the focused welding laser is welded on the workpiece surface according to the welding path.

[0174] Specifically, after receiving a valid level signal corresponding to the welding command, the host MCU can output a matching drive level to the welding laser according to the retrieved welding parameters. The laser generates a laser beam according to the set operating conditions. The laser beam is transmitted to the collimating lens via optical fiber. The collimating lens collimates and focuses the incident laser to obtain a collimated welding laser. The collimated welding laser is transmitted to the focusing lens through the dual galvanometer scanning module. The focusing lens focuses the collimated welding laser to obtain a focused welding laser. This step is used to start laser emission according to predetermined parameters after receiving the welding command, complete the laser directional transmission by optical fiber, and then complete the beam straightening process through the collimating lens and focusing lens to deflect the optical path of the galvanometer module and output a qualified laser beam.

[0175] Laser welding methods, devices, media, and products achieve portable welding of complex patterns through the coordinated control of a dual MCU communication architecture, dual galvanometer scanning modules, collimating lenses, and focusing lenses. This reduces equipment size, improves welding efficiency, and lowers weld uniformity errors. Furthermore, it supports automated welding of various materials such as stainless steel, aluminum, and copper, significantly reducing the operational threshold and equipment costs.

[0176] This embodiment provides a laser welding method that integrates a welding torch, a control host, and a power supply into a single welding structure. This eliminates the need for the large frame and precision tooling required in traditional fixed pattern welding systems, simplifying the equipment structure and reducing manufacturing costs. Welding can be completed without transporting the workpiece to a fixed processing station, overcoming the shortcomings of traditional fixed equipment that is bulky and has limited operating scenarios. By configuring a dual-MCU communication architecture between the host MCU and the welding torch MCU, the host MCU determines the pattern welding mode and autonomously generates the welding path. The laser beam is stably transmitted via fiber optics and then collimated and focused by a collimating lens. The collimated welding laser is transmitted to the focusing lens through a dual-galvanometer scanning module, where the focusing lens focuses the laser. Finally, the welding torch MCU precisely controls the dual-galvanometer scanning module to deflect the optical path, ensuring that the laser focus strictly follows a preset trajectory to complete complex pattern welding on the workpiece surface. This overcomes the shortcomings of traditional welding methods in processing complex welds. Based on this hardware structure and control logic, it balances equipment simplicity with complex pattern welding performance, adapting to diverse and flexible processing scenarios and improving the low efficiency of traditional laser welding operations.

[0177] Figure 2 This is a schematic diagram of the structure of the laser welding apparatus provided in an embodiment of this application. Figure 2 As shown, the laser welding apparatus includes:

[0178] The acquisition module 201 is used to acquire mode signals. If the welding mode is determined to be a graphic welding mode based on the mode signals, the welding graphic and welding parameters are acquired, the welding path is generated according to the welding graphic, and the welding path is sent to the welding torch MCU. The welding torch MCU and the welding laser are both connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber. The dual galvanometer scanning module is connected to the welding torch MCU.

[0179] The control module 202 is used to respond to welding commands and control the welding laser to transmit the welding laser to the collimating lens through an optical fiber based on welding parameters. The collimating lens is used to collimate the welding laser to obtain a collimated welding laser. The collimated welding laser is then transmitted to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated welding laser to obtain a focused welding laser. The welding torch MCU is used to control the dual galvanometer scanning module to deflect the optical path of the focused welding laser so that the focal point of the focused welding laser is welded on the workpiece surface according to the welding path.

[0180] The laser welding apparatus provided in this embodiment can perform... Figure 1 The technical solution of the laser welding method embodiment shown herein, its implementation principle and technical effect are similar to Figure 1 The laser welding method shown in the example is similar and will not be described in detail here.

[0181] Figure 3 This is a schematic diagram of the hardware structure of the electronic device provided in an embodiment of this application. Figure 3 As shown, the electronic device 30 includes at least one processor 301 and a memory 302. The electronic device 30 also includes a communication component 303. The processor 301, memory 302, and communication component 303 are connected via a bus 304.

[0182] In a specific implementation, at least one processor 301 executes computer execution instructions stored in memory 302, causing at least one processor 301 to implement a laser welding method of the above embodiment.

[0183] The specific implementation process of processor 301 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0184] In the above embodiments, it should be understood that the processor 301 can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this invention can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor.

[0185] The memory 302 may include high-speed RAM memory, and may also include non-volatile memory (NVM), such as at least one disk storage.

[0186] Bus 304 can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Bus 304 can be divided into address bus, data bus, control bus, etc. For ease of illustration, the bus 304 in the accompanying drawings of this application is not limited to only one bus or one type of bus.

[0187] The above description of the functions implemented by electronic devices and main control devices has introduced the solutions provided by the embodiments of the present invention. It is understood that, in order to implement the above functions, the electronic device or main control device includes hardware structures and / or software modules corresponding to the execution of each function. By combining the units and algorithm steps of the various examples described in the embodiments of the present invention, the embodiments of the present invention can be implemented in hardware or a combination of hardware and computer software. Whether a function is executed by hardware or by computer software driving hardware depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the technical solutions of the embodiments of the present invention.

[0188] This application also provides a computer-readable storage medium storing computer-executable instructions. When executed by a processor, these instructions are used to implement a laser welding method according to the above embodiments. In a specific implementation of the aforementioned laser welding method, each module can be implemented as a processor.

[0189] The aforementioned readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. The readable storage medium can be any available medium accessible to a general-purpose or special-purpose computer.

[0190] An exemplary readable storage medium is coupled to a processor, enabling the processor to read information from and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can reside in application-specific integrated circuits (ASICs). Alternatively, the processor and the readable storage medium can exist as discrete components in an electronic device or a host device.

[0191] This application also provides a computer program product, including a computer program, which, when executed by a processor, is used to implement a laser welding method according to the above embodiments.

[0192] The computer program is stored in a readable storage medium, and at least one processor can read the computer program from the readable storage medium and execute the computer program to perform the scheme provided in any of the above embodiments.

[0193] Those skilled in the art will understand that all or part of the steps of the above method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When the program is executed, it performs the steps of the above method embodiments; and the aforementioned storage medium includes various media capable of storing program code, such as ROM, RAM, magnetic disk, or optical disk.

[0194] The technical solutions of this application have been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it is readily understood by those skilled in the art that the scope of protection of this application is obviously not limited to these specific embodiments. The above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A laser welding system, characterized in that, include: The welding torch, the control host, and the AC power supply electrically connected to the welding torch and the control host, wherein the control host includes a host MCU and a welding laser, and the welding torch includes a welding torch MCU, a collimating lens, a focusing lens, and a dual galvanometer scanning module; Both the welding torch MCU and the welding laser are communicatively connected to the host MCU. The welding laser is connected to the collimating lens via an optical fiber. The dual galvanometer scanning module is communicatively connected to the welding torch MCU. The host MCU is used to acquire mode signals. If the welding mode is determined to be a graphic welding mode based on the mode signals, the host MCU acquires the welding graphic and welding parameters, generates a welding path according to the welding graphic, and sends the welding path to the welding gun MCU. The host MCU is also used to respond to welding commands, control the welding laser to transmit welding laser to the collimating lens based on the welding parameters, the collimating lens is used to collimate the welding laser to obtain a collimated welding laser, and transmit the collimated welding laser to the focusing lens through the dual galvanometer scanning module, the focusing lens is used to focus the collimated welding laser to obtain a focused welding laser; The welding torch MCU is used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focal point of the focused welding laser welds on the workpiece surface according to the welding path.

2. The laser welding system according to claim 1, characterized in that, The welding torch is equipped with a multi-function button area, which includes a welding start button and a mode knob. Both the welding start button and the mode knob are connected to the host MCU via the welding torch MCU. The host MCU is also used to control the welding laser to switch from the shutdown state to the welding ready state in response to the welding start button being pressed; The welding torch MCU is also used to acquire the state of the mode knob and generate the mode signal based on the state; wherein the mode signal is used to represent the welding mode, which is the graphic welding mode, continuous welding mode or spot welding mode.

3. The laser welding system according to claim 2, characterized in that, The control host is also equipped with a preview laser, which is communicatively connected to the host MCU. The preview laser is connected to the collimating lens via an optical fiber. The multi-function button area is also equipped with a two-stage trigger button, which is connected to the host MCU signal line. The host MCU is also configured to, in response to the first press of the two-stage trigger button, control the preview laser to transmit the preview laser to the collimating lens through an optical fiber based on preset preview parameters. The collimating lens is used to collimate the preview laser to obtain a collimated preview laser, and transmit the collimated preview laser to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated preview laser to obtain a focused preview laser. The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused preview laser to scan the welding path on the workpiece surface; The host MCU is also configured to control the welding laser to transmit welding laser to the collimating lens based on the welding parameters in response to the second pressing of the two-stage trigger button; wherein, the welding command refers to the second pressing of the two-stage trigger button, and the second pressing of the two-stage trigger button is used to indicate that the welding path scanned on the surface of the workpiece is correct.

4. The laser welding system according to claim 3, characterized in that, When the host MCU determines that the welding mode is a pattern welding mode based on the mode signal, it is specifically used for: Obtain the welding pattern, the type of material required for welding, and the welding thickness; The matching degree between the welding pattern, the type of material required for welding, and the welding thickness and multiple preset parameter packages is calculated, and the parameters in the preset parameter package corresponding to the maximum matching degree are determined as the welding parameters; wherein, the welding parameters include initial laser power, initial pulse frequency, initial duty cycle, and initial scanning speed.

5. The laser welding system according to claim 4, characterized in that, The welding torch MCU is used to acquire the real-time welding speed and send the real-time welding speed to the host MCU; The host MCU is also used to acquire real-time laser power and real-time pulse frequency, and adjust the real-time laser power and real-time pulse frequency according to the real-time welding speed so that the laser energy per unit length of weld is constant.

6. The laser welding system according to claim 5, characterized in that, The welding torch MCU is also used to acquire the real-time attitude of the welding torch during the welding process and the initial attitude of the welding torch before welding begins, and send the real-time attitude and the initial attitude to the host MCU; The host MCU is also used to calculate the welding gun attitude offset based on the real-time attitude and the initial attitude. If the welding gun attitude offset is less than or equal to a preset offset threshold, the welding path is corrected based on the welding gun attitude offset to obtain a corrected welding path, and the corrected welding path is sent to the welding gun MCU. The welding torch MCU is also used to control the dual galvanometer scanning module to deflect the focused welding laser, so that the focus of the focused welding laser welds on the workpiece surface according to the corrected welding path.

7. The laser welding system according to claim 6, characterized in that, It also includes a rectifier power supply, a first step-down circuit, a second step-down circuit, and a third step-down circuit. The AC power supply and the welding laser are both electrically connected to the rectifier power supply. The AC power supply and the second step-down circuit are both electrically connected to the first step-down circuit. The second step-down circuit is electrically connected to the host MCU. The first step-down circuit and the welding torch MCU are both electrically connected to the third step-down circuit. The welding torch MCU is also used to acquire the temperature of the welding torch and the first fluctuation amplitude of the output power of the rectifier power supply, and send the first fluctuation amplitude to the host MCU; The welding torch MCU is also used to send a first alarm signal to the host MCU when the welding torch attitude offset is greater than a preset offset threshold or the temperature is greater than a preset temperature threshold. The host MCU is also used to obtain the second fluctuation amplitude of the real-time laser power, and generate a second alarm signal when the first fluctuation amplitude is greater than a preset first amplitude threshold or the second fluctuation amplitude is greater than a preset second amplitude threshold. The host MCU is also used to trigger preset protection measures corresponding to the alarm type based on the alarm type of the first alarm signal and the second alarm signal.

8. The laser welding system according to claim 7, characterized in that, It also includes a fourth step-down circuit. The dual galvanometer scanning module includes a galvanometer motor. The galvanometer motor and the first step-down circuit are both electrically connected to the fourth step-down circuit. The welding torch is provided with a welding torch housing and a welding torch air duct. The control host is provided with a host housing, a host air duct and a fan. The fan is electrically connected to the host MCU. The host MCU is used to output a PWM speed control signal to the fan to adjust the fan speed. The first air inlet and the first air outlet of the welding torch air duct are both located on the welding torch housing. External air enters the welding torch air duct from the first air inlet, flows through the sealed housing of the galvanometer motor, collimating lens and focusing lens, and then exits the welding torch air duct from the first air outlet. The second air inlet and the second air outlet of the host air duct are both located on the host housing. The fan is located inside the host air duct. The fan is used to draw in external air and deliver the external air to the welding laser through the airflow generated by the fan rotation. The external air is used to absorb the heat of the welding laser and then discharged from the host air duct through the second air outlet.

9. The laser welding system according to claim 8, characterized in that, The welding laser is equipped with a temperature sensor, which is electrically connected to the host MCU. The temperature sensor is used to collect the temperature signal of the welding laser, convert the temperature signal into an analog voltage, and send the analog voltage to the host MCU. The host MCU is used to convert the analog voltage into temperature and adjust the speed of the fan according to the temperature.

10. The laser welding system according to claim 9, characterized in that, The welding torch MCU is also used to send a welding completion signal to the host MCU in response to the fact that the focus of the focused welding laser has traversed the welding path; The host MCU is also used to control the welding laser to stop operating in response to the welding completion signal.

11. The laser welding system according to claim 10, characterized in that, The welding torch is equipped with a status indicator module, which is connected to the welding torch MCU signal line. The welding torch MCU is also used for: In response to the AC power supply starting to power the first step-down circuit, the status indicator module is controlled to output a power-on light prompt. In response to the welding laser switching from the shutdown state to the welding standby state, the status indicator module is controlled to output a standby status light prompt. In response to the first alarm signal or the second alarm signal, the status indicator module is controlled to output a fault alarm light prompt. In response to the welding completion signal, the status indicator module is controlled to output a light prompt indicating that the job is completed.

12. A laser welding method, characterized in that, The method is applied to a host MCU in a laser welding system as described in any one of claims 1 to 11, the method comprising: The mode signal is acquired. If the welding mode is determined to be a graphic welding mode based on the mode signal, the welding graphic and welding parameters are acquired. A welding path is generated according to the welding graphic and the welding path is sent to the welding gun MCU. The welding gun MCU and the welding laser are both communicatively connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber. The dual galvanometer scanning module is communicatively connected to the welding gun MCU. In response to a welding command, the welding laser is controlled to transmit welding laser light through an optical fiber to the collimating lens based on the welding parameters. The collimating lens is used to collimate the welding laser light to obtain a collimated welding laser light. The collimated welding laser light is then transmitted to the focusing lens through the dual galvanometer scanning module. The focusing lens is used to focus the collimated welding laser light to obtain a focused welding laser light. The welding torch MCU is used to control the dual galvanometer scanning module to deflect the optical path of the focused welding laser light so that the focal point of the focused welding laser light is aligned with the welding path on the workpiece surface for welding.

13. A laser welding apparatus, characterized in that, The device is located in the host MCU of the laser welding system as described in any one of claims 1 to 11, and the device comprises: The acquisition module is used to acquire mode signals. If the welding mode is determined to be a graphic welding mode based on the mode signals, the welding graphic and welding parameters are acquired, a welding path is generated according to the welding graphic, and the welding path is sent to the welding torch MCU. The welding torch MCU and the welding laser are both communicatively connected to the host MCU. The welding laser is connected to the collimating lens through an optical fiber, and the dual galvanometer scanning module is communicatively connected to the welding torch MCU. A control module, in response to a welding command, controls the welding laser to transmit welding laser light through an optical fiber to the collimating lens based on the welding parameters. The collimating lens collimates the welding laser light to obtain a collimated welding laser, and transmits the collimated welding laser light to the focusing lens through the dual-galvanometer scanning module. The focusing lens focuses the collimated welding laser light to obtain a focused welding laser. The welding torch MCU controls the dual-galvanometer scanning module to deflect the focused welding laser light path so that the focal point of the focused welding laser light welds onto the workpiece surface according to the welding path.

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