Ranging system for laser welding tool and laser welding system

Abstract

The utility model relates to a distance measuring system for a laser welding tool and a laser welding system. A ranging system for a laser welding tool includes a laser-based ranging device that is moved into and out of respective beam envelopes that contain one or more laser welding beams for performing welding. In some embodiments, a ranging system of the present disclosure includes a coupling mechanism for coupling one or more ranging devices to a laser welding tool, where the coupling mechanism alternately moves the ranging device from a welding position to a ranging position, or allows the ranging device to alternately move between these positions. The ranging system of the present disclosure obtains an accurate and precise ranging distance that facilitates precise positioning of the focus of each laser welding beam with respect to each welding site to minimize the occurrence of erroneous forming welds from incorrect focus positioning. A laser welding system comprising such a ranging system is also disclosed.

Description

Technical Field

[0001] The present disclosure generally relates to the field of welding. In particular, the present disclosure relates to a ranging system for a laser welding tool and related systems and methods for laser welding workpieces. Background Art

[0002] A secondary battery cell typically includes a stacked core composed of alternately stacked cathodes and anodes that are electrically separated from each other, where the cathode is electrically connected to a cathode cell output tab and the anode is electrically connected to an anode cell output tab. These cells are typically used to manufacture multi-cell battery modules, where multiple battery cells are arranged in a stacked manner and adjacent cell output tabs are electrically and physically connected to each other. Typically, these connections are achieved by laser welding the cell output tabs together.

[0003] Laser welding requires the focus of the laser beam that produces the weld to be precisely positioned in terms of the distance from the laser welding tool. If the distance is not suitable for producing the necessary focus, the resulting weld may be defective due to overheating or underheating, as the case may be. Due to any one or more of a variety of factors, including but not limited to the imprecise bending of the cell output tabs that create the well area, the imprecise positioning of the cell stack within the welding fixture, and the repeatability error of any robotic manipulator that positions the cell stack for the welding process, there is some variability at the weld site, which is also in terms of the distance from the laser welding tool, and thus challenges arise during the laser welding process. Distance errors as small as 1 mm to 2 mm can result in suboptimal welds.

[0004] To ensure high-quality welding, it is necessary to ensure that the distance between the laser welding tool and the area on the cell output tab to be welded is optimal, because the positioning of the laser spot of the welding beam relative to the weld site is crucial for performing high-quality welding. However, there is no convenient and precise method to make the necessary measurements to confirm / set this distance. Most methods rely on manual measurement. However, manual measurement easily results in errors of 1 mm or greater. Summary of the Utility Model

[0005] In one embodiment, the present disclosure relates to a ranging system for a laser welding tool that welds a workpiece at a welding site by emitting a welding beam along a beam path. The ranging system includes: a ranging device designed and configured to determine a ranging distance to the welding site when the ranging system is deployed and used during a welding operation; and a coupling mechanism designed and configured to couple the ranging device in a fixed relationship relative to the laser welding tool such that: at least a portion of the ranging device is located at a ranging position in the beam path when the ranging device determines the ranging distance; and the ranging device is located at a welding position outside the beam path when the laser welding tool emits the welding beam for the welding.

[0006] In some embodiments, the coupling mechanism includes a reciprocating mechanism operably coupled to the ranging device and configured to reciprocate the ranging device between the welding position and the ranging position.

[0007] In some embodiments, the coupling mechanism includes a support for fixedly securing the coupling mechanism to the laser welding tool, and the reciprocating mechanism includes: one or more guide rails fixedly secured to the support; and a reciprocating member slidably engaged with the one or more guide rails, the ranging device being fixedly mounted to the reciprocating member; wherein the one or more guide rails and the reciprocating member are designed and configured such that the reciprocating member is capable of reciprocating along the one or more guide rails to move the ranging device between the welding position and the ranging position.

[0008] In some embodiments, the reciprocating mechanism includes a rotation axis about which the ranging device pivots as the ranging device moves between the welding position and the ranging position.

[0009] In some embodiments, the reciprocating mechanism includes an actuator coupled to the ranging device to reciprocate the ranging device between the welding position and the ranging position.

[0010] In some embodiments, the ranging system further includes a control system operatively communicating with the actuator to move the reciprocating member by the actuator to move the ranging device between the welding position and the ranging position.

[0011] In some embodiments, the coupling mechanism further includes a first adjustment mechanism for adjusting the positioning of the ranging device relative to the laser welding tool.

[0012] In some embodiments, the ranging system further includes a control system that uses the ranging distance to calculate a welding distance (WD) to the focus of the laser welding beam.

[0013] In some embodiments, the control system determines whether the welding distance is within a predetermined tolerance.

[0014] In some embodiments, the control system outputs an indication of whether the welding distance is within the predetermined tolerance.

[0015] In another embodiment, the present disclosure relates to a laser welding system that includes: a laser welding tool configured to weld a workpiece at a welding site by emitting a welding beam along a beam path; and a ranging system that includes a ranging device and a coupling mechanism, the ranging device being designed and configured to determine a ranging distance to the welding site when the ranging system is used during a welding operation, the coupling mechanism being designed and configured to couple the ranging device in a fixed relationship relative to the laser welding tool such that: at least a portion of the ranging device is located at a ranging position in the beam path when the ranging device determines the ranging distance; and the ranging device is located at a welding position outside the beam path when the laser welding tool emits the welding beam to perform the welding.

[0016] In some embodiments, the coupling mechanism includes a reciprocating mechanism operatively coupled to the ranging device and configured to reciprocate the ranging device between the welding position and the ranging position.

[0017] In some embodiments, the coupling mechanism includes a support for fixedly securing the coupling mechanism to the laser welding tool, and the reciprocating mechanism includes: one or more guide rails fixedly secured to the support; and a reciprocating member slidably engaged with the one or more guide rails, the ranging device being fixedly mounted to the reciprocating member; wherein the one or more guide rails and the reciprocating member are designed and configured such that the reciprocating member is capable of reciprocating along the one or more guide rails to move the ranging device between the welding position and the ranging position.

[0018] In some embodiments, the reciprocating mechanism includes a rotational axis about which the ranging device pivots as the ranging device moves between the welding position and the ranging position.

[0019] In some embodiments, the reciprocating motion mechanism includes an actuator that is coupled to the distance measuring device to reciprocate the distance measuring device between the welding position and the distance measuring position.

[0020] In some embodiments, the laser welding system further includes a control system that is operatively communicable with the actuator to move the reciprocating member by the actuator, thereby moving the distance measuring device between the welding position and the distance measuring position.

[0021] In some embodiments, the coupling mechanism further includes a first adjustment mechanism for adjusting the positioning of the distance measuring device relative to the laser welding tool.

[0022] In some embodiments, the laser welding system further includes a control system that calculates a welding distance to the focus of the laser welding beam using the measured distance.

[0023] In some embodiments, the control system determines whether the welding distance is within a predetermined positioning tolerance.

[0024] In some embodiments, the control system outputs an indication of whether the welding distance is within the predetermined positioning tolerance.

[0025] In some embodiments, the laser welding system further includes at least one actuator for adjusting the welding distance, wherein the control system controls the at least one actuator such that the welding distance is within the predetermined positioning tolerance.

[0026] In yet another embodiment, the present disclosure relates to a method of determining a measured distance to a welding site for laser welding a workpiece with a laser welding beam having a beam path. The method includes: moving a distance measuring device into the beam path; operating the distance measuring device to obtain the measured distance when the distance measuring device is in the beam path; and after obtaining the measured distance, moving the distance measuring device out of the beam path.

[0027] In some embodiments, moving the distance measuring device into and out of the beam path includes translating the distance measuring device in a plane perpendicular to the beam path.

[0028] In some embodiments, moving the distance measuring device into and out of the beam path includes rotationally moving the distance measuring device.

[0029] In some embodiments, the movement of the distance measuring device is performed automatically.

[0030] In some embodiments, the movement of the distance measuring device is automatically coordinated with forming the laser weld.

[0031] In another embodiment, the present disclosure relates to a method of laser welding a workpiece with a laser welding beam having a beam path. The method includes: moving a ranging device into the beam path; when the ranging device is in the beam path, operating the ranging device to obtain a ranging distance to a welding site on the workpiece; after obtaining the ranging distance, moving the ranging device out of the beam path; and after moving the ranging device out of the beam path, causing the laser welding beam to perform the laser welding on the workpiece.

[0032] In some embodiments, moving the ranging device into and out of the beam path includes translating the ranging device in a plane perpendicular to the beam path.

[0033] In some embodiments, moving the ranging device into and out of the beam path includes rotationally moving the ranging device.

[0034] In some embodiments, the movement of the ranging device is performed automatically.

[0035] In some embodiments, the movement of the ranging device is automatically coordinated with forming the laser weld.

[0036] In some embodiments, the method further includes determining a welding distance from a laser welding tool to the welding site based on the ranging distance.

[0037] In some embodiments, the method further includes determining whether the welding distance is within a predetermined tolerance.

[0038] In some embodiments, the method further includes adjusting a welding distance between a laser welding tool and the welding site based on the ranging distance. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] For purposes of illustration, the drawings show aspects of one or more embodiments of the present disclosure. However, it is to be understood that the scope of the present disclosure is not limited to the exact arrangements and instrumentalities shown in the drawings, where:

[0040] Figure 1 is a partial high-level block diagram / partial schematic view of an exemplary laser welding system made in accordance with aspects of the present disclosure;

[0041] Figure 2 is an isometric view of an exemplary laser welding system configured to weld electrode tabs of an electrochemical cell when assembling a secondary battery cell (workpiece), where the laser welding system includes an exemplary ranging system that accurately and precisely measures one or more distances from a laser welding tool to the workpiece; and

[0042] Figure 3A Is Figure 2 An enlarged front view of a workpiece and a corresponding welding fixture, showing example checkpoints at which a ranging system obtains ranging data;

[0043] Figure 3B Is of Figure 2 An isometric view of a laser welding system without a ranging system added, showing an example laser welding tool and a workpiece to be welded; and

[0044] Figure 4 Is Figure 2 An enlarged view of an example laser ranging system of Detailed Description

[0045] The entire contents of the appended claims are incorporated by reference into this detailed description section and should be considered as if originally presented herein.

[0046] Overview

[0047] In some aspects, the present disclosure relates to a ranging system that can be used with a laser welding tool to accurately determine one or more welding distances from the laser welding tool to a workpiece in order to accurately set the focus of one or more laser beams for corresponding welding on the workpiece. As used herein and in the appended claims, the term "welding distance" and like terms denote the distance between the laser welding tool and the welding site on the workpiece to be welded (i.e., the distance between the laser welding tool and the welding site where the focus of the laser beam at the welding site needs to be optimized, which will result in a good weld). The welding distance can be the distance between the welding site and any suitable reference location (e.g., a location on the ranging device or a location on the welding tool), which can be used to determine that the focus location substantially coincides with the welding site.

[0048] As discussed below, the ranging system of the present disclosure includes at least one degree of freedom for moving a ranging device into and out of the welding beam path of a laser welding tool in order to obtain highly accurate ranging data related to the welding distance substantially along the beam path of the laser welding tool. As also discussed below, the ranging system of the present disclosure can provide one or more additional degrees of freedom to accommodate various adjustments (e.g., one or more adjustments for achieving different focus locations and one or more adjustments for positioning the ranging device in a plane perpendicular to the beam axis of the welding tool). In the example below, the workpiece is a stack of secondary battery cells, and the cell output tabs of adjacent cell pairs are welded to the secondary battery cells in order to electrically and physically connect the secondary battery cells to each other. However, in other examples, the workpiece can actually be any object that requires at least one laser form welding or "laser welding".

[0049] In some aspects, the present disclosure relates to a method of determining a ranging distance located substantially along a beam path of a laser welding tool by moving a ranging device into and out of a welding beam envelope of the laser welding tool. The movement of the ranging device can be accomplished in any suitable manner, such as by linear or curvilinear translation of the ranging device, or by pivoting the ranging device, or a combination of translation and pivoting, and so on. Such a method can also include operating a ranging system to measure the ranging distance and then using the ranging distance to determine a welding distance. In some embodiments, the ranging distance is the welding distance. In some embodiments, the welding distance is equal to the sum of the ranging distance and a predetermined distance (PD) (e.g., the distance between the positioning of the ranging device and the positioning on the laser welding tool). Some methods of the present disclosure can also include adjusting the positioning of the ranging device to accommodate different laser focal lengths (e.g., when using a ranging system with different laser welding tools). Some methods of the present disclosure can also include adjusting the positioning of the ranging device in one or more directions perpendicular to the nominal beam path of the welding beam envelope. In some aspects, the present disclosure relates to a method of forming a laser weld using the ranging system of the present disclosure. The foregoing and other aspects are illustrated below and / or in the appended claims.

[0050] Example embodiments

[0051] Turning now to the drawings, Figure 1 There is shown an example laser welding system 100 of the present disclosure. In this example, the laser welding system 100 includes a ranging system 104 and a laser welding tool 108 for forming a laser weld 112 on a workpiece 116 (as described above, the workpiece 116 can be any suitable workpiece, including an electrochemical cell stack for forming a secondary battery, etc.). The laser welding tool 108 can be any suitable laser welding tool for generating a laser weld (e.g., laser weld 112). Those skilled in the art will be familiar with the objects to be welded suitable for the workpiece 116 and the laser welding tools suitable for use as the laser welding tool 108 such that the broad scope of the present disclosure can be understood by those skilled in the art without further explanation.

[0052] In this example, the laser welding tool 108 has a laser beam envelope 120 that has a nominal beam path 120A and includes at least one laser beam 120B during a welding operation to form a weld 112. The ranging system 104 includes a ranging device 124 that includes one or more ranging lasers 124L and one or more ranging sensors 124S and is configured to measure one or more ranging distances, such as the illustrated ranging distance RD. The ranging system 104 also includes a linkage mechanism 128 that is configured to have at least one degree of freedom that allows the linkage mechanism to repeatedly move the ranging device 124 into and out of the welding beam envelope 120. The linkage mechanism 128 moves the ranging device 124 into the welding beam envelope 120 for making one or more measurements of the ranging distance RD. Because the ranging device 124 makes measurements within the welding beam envelope 120, the measurements can be highly accurate and precise for determining the weld location of the weld 112, since the weld 112 is positioned between the laser welding tool 108 and the weld location substantially along the path of the laser beam 120B that will be used to make the weld. When the laser welding system 100 uses the laser beam 120B to make the weld 112, the linkage mechanism 128 moves the ranging device 124 out of the welding beam envelope 120 so as not to block or otherwise interfere with the laser beam. Figure 1 The ranging device 124 is shown in each of a ranging position (lower and blocking the path of the laser beam 120B) and a welding position (higher and not blocking the path of the laser beam). Those skilled in the art will readily understand that Figure 1 the illustrated welding position is merely exemplary, and other welding positions may be used. Generally, the only requirement is that no portion of the ranging device 124 interferes with the welding beam 120B during welding.

[0053] In an example, the coupling mechanism 128 can have a single linear or curvilinear degree of freedom for moving the ranging device 124 between the ranging position and the welding position of the ranging device 124. Such a linear degree of freedom can be provided to move the ranging device 124 parallel to the shown y-z plane, for example, parallel to the z-axis, parallel to the y-axis, or in any other direction parallel to the y-z plane. The coupling mechanism 128 can include any suitable mechanism for providing such linear motion, such as a track-type mechanism or a linear actuator, etc. If a track-type mechanism is used, the track member can be linear or curvilinear. In another example, the coupling mechanism can have a single rotational degree of freedom for moving the ranging device 124 between the ranging position and the welding position of the ranging device 124. Such a rotational degree of freedom can be provided to move the ranging device 124, for example, about an axis parallel to any one of the shown x-axis, y-axis, and z-axis, or any other suitable axis. The coupling mechanism 128 can include any suitable mechanism for providing such rotational motion, such as a stepper motor, a servo motor, or any other type of rotational actuator. In other examples, the coupling mechanism 128 can be configured to move the ranging device 124 between the ranging position and the welding position of the ranging device 124 using one or more mechanisms providing any two or more suitable degrees of freedom. All that is required is that the coupling mechanism 128 be able to move the ranging device 124 in a manner that enables ranging and welding and does not interfere with any other aspects of the laser welding system 100, and those skilled in the art will readily understand how to configure any suitable coupling mechanism to perform these functions. In some embodiments, this portion of the coupling mechanism 128 that moves the ranging device 124 between the welding position and the ranging position is referred to as a "shuttling mechanism" because the motion has a reciprocating or "shuttle-like" nature, regardless of the characteristics of the motion, i.e., whether the motion is rotational or translational.

[0054] The ranging device 124 includes at least one ranging laser 124L and at least one complementary ranging sensor 124S for measuring the ranging distance RD. Each of the ranging lasers 124L and each of the ranging sensors 124S can be any suitable ranging laser and ranging sensor respectively (including any commercially available off-the-shelf ranging lasers and ranging sensors, etc.). Those skilled in the art will readily understand the types of ranging lasers and ranging sensors suitable for use with the ranging device of the present disclosure (such as Figure 1 the ranging device 124), such that it is not necessary to describe further details herein for those skilled in the art to manufacture and use the ranging systems and laser welding systems of the present disclosure (such as any ranging systems 104 and 204 and any laser welding systems 100 and 200 of the present disclosure).

[0055] In some embodiments, the coupling mechanism 128 may include one or more degrees of freedom in addition to the degrees of freedom provided to move the ranging device between the ranging position and the welding position of the ranging device. For example, the coupling mechanism 128 may be configured to provide a linear degree of freedom in a direction parallel to the illustrated x-axis. This degree of freedom may be provided, for example, for fine-tuning along the nominal beam path 120A and / or for adjusting the ranging system 104 to a different laser tool focal length. As another example, the coupling mechanism 128 may have one or more additional degrees of freedom in a plane parallel to the illustrated y-z plane (e.g., for in-plane adjustment and / or, if multiple ranging lasers 124L and / or multiple ranging sensors 124S are provided, for deploying one or more other pairs or combinations of ranging lasers and ranging sensors). Those skilled in the art will understand how to implement any such additional features.

[0056] In this example, the ranging system 104 includes a control system 132 that determines whether the focus of each laser beam 120B coincides with the positioning of the corresponding weld 112 within an acceptable tolerance (e.g., + / - 1 mm and other values). In some embodiments, the laser welding system 100 may be configured to make any necessary adjustments before the laser welding tool 108 is energized to perform the weld 112 so that the focus of the laser beam 120B is within an acceptable tolerance. For example, the laser welding system 100 may include one or more controlled actuators (e.g., servo motors, stepper motors, linear actuators, etc.) for moving the laser welding tool 108 or the workpiece 116, or both the laser welding tool and the workpiece, until the focus is available for performing the weld 112. In such embodiments, the control system 132 may use feedback control to operate the controlled actuators. Those skilled in the art will readily understand how to perform such feedback control within the control system 132 using only knowledge of the art and the present disclosure as a guide.

[0057] In some embodiments, the coupling mechanism 128 may be configured for only manual movement of the ranging device 124. In such embodiments, the control system 132 may include controls (not shown; e.g., soft buttons or hard buttons, etc.) that allow the user to cause the ranging device 124 to make one or more measurements, and include one or more indicators (not shown; e.g., graphical display, LED indicator, audible indicator, etc.) indicating whether the focus of the laser beam 120B is within an acceptable tolerance.

[0058] In some embodiments, the control system 132 may also be configured to move the ranging device 124 between the ranging position and the welding position of the ranging device 124, for example, automatically (e.g., in conjunction with the automated operation of the laser welding tool 108) or semi-automatically (e.g., in response to a user input of an appropriate "move" command). For example, the coupling mechanism 128 may include one or more controlled actuators 136 (such as servo motors, stepper motors, linear actuators, etc.) for moving the ranging device 124. In some embodiments, the movement of the ranging device between the ranging position and the welding position of the ranging device may be manual and performed by a user of the laser welding system.

[0059] The control system 132 may include any suitable hardware and software for providing the necessary functionality for a particular illustration of the laser welding system 100 discussed. Those skilled in the art will readily understand the types of hardware and software required for the control system 132 provided for a particular illustration and will further understand how to code any necessary machine-executable instructions for providing such functionality. Note that although Figure 1 the control system 132 is depicted as part of the ranging system 104, one or more or all aspects of the control system 132 may be provided outside of the ranging system.

[0060] In some embodiments, one, the other, or both of the laser welding tool 108 and the workpiece 116 may be fixed or movable. For example, in an example, the laser welding tool 108 is fixedly attached to a fixed structure (not shown), while the workpiece 116 is movable relative to the fixed laser welding tool (e.g., using a robotic manipulator (not shown) and / or other systems (such as a conveyor system, etc.)). In some embodiments, a robotic manipulator may be used to correctly position the workpiece 116 or the assembly of the workpiece and the welding fixture relative to the laser welding tool 108. Such positioning may include ensuring that the ranging distance RD is appropriate to allow the laser welding tool 108 to form a high-quality weld on the workpiece 116 in addition to the overall movement of the workpiece or the workpiece + welding fixture into and out of the welding position of the workpiece or the workpiece + welding fixture. As another example, the laser welding tool 108 may be coupled to a fixed support (not shown) via an adjustment mechanism (not shown) that moves the laser welding tool as needed to, for example, adjust the ranging distance RD and / or perform any other desired position adjustment of the laser welding tool. As a further example, an adjustment mechanism for the laser welding tool 108 and a robotic manipulator and / or other systems for the workpiece or the workpiece + welding fixture may be provided.

[0061] Figures 2 to 4Shows an example laser welding system 200 having a manually operated rangefinding system 204 manufactured in accordance with aspects of the present disclosure. In this example, the laser welding system 200 includes a laser welding tool 208 for welding a workpiece 212, which is securely held in a welding fixture 216 in this example. Figure 3A Shows details of the workpiece 212 and the welding fixture 216 associated with the example laser welding system 200.

[0062] Reference Figure 3A , in this example, the workpiece 212 is a secondary battery cell 300, which includes a stack of pouch-type electrochemical cells (not shown) (e.g., lithium metal cells or lithium-ion cells, etc.), and the electrochemical cells have electrode tabs 304, and adjacent electrode tabs among the electrode tabs 304 are bent to overlap each other. It is these bent and overlapping tab ears 304 Figure 2 of the laser welding system 200 that are electrically and physically connected together by welding on the surface facing Figure 3A the observer. The welding fixture 216 includes a front plate 308, which holds the overlapping tab ears 304 in proper positions relative to each other for welding and has holes 312 (only a few are marked to avoid cluttering the figure), through which a laser welding beam (not shown) is irradiated to produce the necessary welding (not shown). In this example, the rangefinding system 204 ( Figure 2 ) is designed and configured to measure a ranging distance (not shown, but see Figure 1 for the ranging distance RD) at a set of inspection points 316L (left) and 316R (right) (only a few of each are marked to avoid cluttering the figure), and these inspection points correspond to the positions on the tab ears 304 where the laser welding tool 208 ( Figure 2 ) will form welds. As will be readily understood by those skilled in the art, the workpiece 212 and the welding fixture 216 in this example are merely illustrative and not restrictive.

[0063] Figure 3B Shows the laser welding system 200 without the rangefinding system 204 ( Figure 2 ) to more clearly show the relationship between the laser welding tool 208 and the workpiece 212 + welding fixture 216. In this example, the laser welding system 200 includes a conveyor 226 for conveying the welding fixture 216 and the workpiece 212 to a position close to the shown welding position before the welding operation and for receiving and moving the welding fixture + workpiece after the welding operation.

[0064] Although not shown, the welding system 200 can include a robotic manipulator having an end effector that engages the welding fixture 216. The robotic manipulator is configured and controlled to move the welding fixture 216 and the workpiece 212 held thereby into and out of the welding position of the welding fixture 216 and the workpiece 212 and into and out of other positions within the welding system. For example, prior to a welding operation, the robotic manipulator can be configured and controlled to pick up the welding fixture 216 and the workpiece 212 from the conveyor 226 before moving the welding fixture+workpiece to the shown welding position, and then move the welding fixture+workpiece to the welding position. Then, after the welding operation, the robotic manipulator can be configured and controlled to move the welding fixture 216 and the workpiece 212 from the shown welding position and place the welding fixture+workpiece back on the conveyor 226. This is just one of many examples of moving the welding fixture 216 and the workpiece 212 into and out of the welding site.

[0065] Referring again to Figure 2 , in this example, the laser welding tool 208 is movably mounted to the fixed support 220 via an adjustable mounting system 224 that provides three translational degrees of freedom respectively parallel to the shown x-axis, y-axis, and z-axis. The adjustable mounting system 224 can be adjusted automatically and / or manually according to design specifications. The adjustable mounting system 224 can be used for any suitable purpose, such as adjusting the distance between the laser welding tool 208 and the workpiece 212 to set the focus of any associated laser welding beam and / or adjusting the position of the laser welding tool to accommodate a laser welding tool with a different focal length, etc. Those skilled in the art will readily understand how to design, configure, and construct the adjustable mounting system 224 to meet the corresponding design specifications.

[0066] The ranging system 204 includes a ranging head 228 and a coupling mechanism 232 that, in this embodiment, couples the ranging head 228 to the laser welding tool 208 and, in this example, allows the ranging head to move along three translational degrees of freedom respectively parallel to the shown x-axis, y-axis, and z-axis. In this example, the coupling mechanism 232 includes a mount 236, a pair of slide bars 240(1) and 240(2), a multi-position bracket 244, and an equipment bracket 248. As Figure 2 shown, the ranging head 228 is shown in three different non-simultaneous positions, namely the welding position 228W, the first ranging position 228R(1), and the second ranging position 228R(2), enabled by the coupling mechanism 232 as described in detail below. When the ranging head 228 is in each of the first ranging position 228R(1) and the second ranging position 228R(2) (and other ranging positions not shown), the ranging head is generally at least partially within the beam envelope (not shown, but see Figure 1 the beam envelope 120) of the laser welding tool 208.

[0067] Reference Figure 4 , in this example, the mounting member 236 fixedly secures the coupling mechanism 232 to the laser welding tool 208. A pair of slide bars 240(1) and 240(2) are movably secured to the mounting member 236 by a pair of threaded fasteners 400 and 404, and each of the threaded fasteners 400 and 404 can be mounted in any one of three corresponding holes 408 and 412 within respective recesses 416(1) and 416(2). Each set of holes 408 and 412 provides adjustability of the coupling mechanism 232 in a direction parallel to the illustrated y-axis (as shown by the double-headed arrow 420). In this example, the adjustability of the coupling mechanism 232 in the direction of the double-headed arrow 420 is manually performed. In other embodiments, such adjustability can be automatically performed using one or more suitable actuators (not shown).

[0068] The multi-position bracket 244 is movably secured to the slide bars 240(1) and 240(2) by a pair of sliders 424(1) and 424(2), and the sliders 424(1) and 424(2) can be locked to a fixed position by respective locking screws 428, 432. The ability of the sliders 424(1) and 424(2) to move along the slide bars 240(1) and 240(2) provides adjustability of the coupling mechanism 232 in a direction parallel to the illustrated x-axis (as shown by the double arrow 436). In this example, the adjustability of the coupling mechanism 232 in the direction of the double-headed arrow 436 is manually performed. In other embodiments, such adjustability can be automatically performed using one or more suitable actuators (not shown).

[0069] The device bracket 248 is movably secured to the multi-position bracket 244, for example via a slide rail 244R( Figure 2 ), so as to provide the necessary mobility to the ranging head 228 in a direction parallel to the Figure 4 illustrated z-axis (as shown by the double-headed arrow 440). The mobility of the ranging head 228 in the direction of the double-headed arrow 440 is manually performed. In other embodiments, such adjustability can be automatically performed using one or more suitable actuators (not shown).

[0070] Same as Figure 2 Figure 4 ​The ranging head 228 is shown at the welding position 228W and each of the first ranging position 228R(1) and the second ranging position 228R(2) (only marked at the second ranging position 228R(2)). In this example, the ranging head 228 includes a pair of laser ranging devices 444L (left) and 444R (right) (only marked at the second ranging position 228R(2)), and the laser ranging devices 444L (left) and 444R (right) respectively emit ranging laser beams 444B(L) and 444B(R). In this example, the ranging laser beams 444B(L) and 444B(R) are respectively used to measure Figure 3A the ranging distances at the inspection points 316L and 316R.

[0071] Various modifications and additions can be made without departing from the spirit and scope of the present disclosure. The features of each of the above-described various embodiments can be appropriately combined with the features of other described embodiments to provide various combinations of features in related new embodiments. In addition, although the foregoing describes multiple individual embodiments, the content described herein merely illustrates the application of the principles of the present invention. Additionally, although the specific methods herein may be illustrated and / or described as being performed in a specific order, within the scope of those skilled in the art, the ordering is highly variable to achieve aspects of the present disclosure. Accordingly, this description is meant to be taken only as an example and does not otherwise limit the scope of the present invention.

[0072] Exemplary embodiments have been disclosed above and shown in the drawings. Those skilled in the art will understand that various changes, omissions, and additions can be made to the specifically disclosed content herein without departing from the spirit and scope of the present invention.

Claims

1. A distance measurement system for a laser welding tool, the laser welding tool being used to weld a workpiece at a welding position by emitting a welding beam along a beam path, characterized in that: The ranging system comprises: a ranging device designed and configured to determine a ranging distance to the welding location when the ranging system is deployed and used during a welding operation; and A coupling mechanism designed and configured to couple the distance measuring device in a fixed relationship relative to the laser welding tool so that: When the ranging device determines the ranging distance, at least a portion of the ranging device is located at a ranging position in the beam path; and When the laser welding tool emits the welding beam to perform welding, the distance measuring device is located at a welding position outside the beam path.

2. The distance measurement system according to claim 1, characterized in that: The coupling mechanism includes a reciprocating mechanism operably coupled to the ranging device and configured to reciprocate the ranging device between the welding position and the ranging position.

3. The distance measurement system according to claim 2, characterized in that: The coupling mechanism comprises a support for fixedly fixing the coupling mechanism to the laser welding tool, and the reciprocating mechanism comprises: one or more guide rails fixedly secured to the support; and a reciprocating member slidably engaged with the one or more rails, the distance measuring device being fixedly mounted to the reciprocating member; The one or more guide rails and the reciprocating member are designed and configured so that the reciprocating member can reciprocate along the one or more guide rails, thereby moving the distance measuring device between the welding position and the distance measuring position.

4. The distance measurement system according to claim 2, characterized in that: The reciprocating mechanism includes an axis of rotation about which the ranging device pivots as the ranging device moves between the welding position and the ranging position.

5. The distance measurement system according to claim 3, characterized in that: The reciprocating mechanism includes an actuator coupled to the ranging device to reciprocate the ranging device between the welding position and the ranging position.

6. The distance measurement system according to claim 5, characterized in that: The ranging system also includes a control system in operative communication with the actuator to cause the actuator to move the shuttle to move the ranging device between the welding position and the ranging position.

7. The distance measurement system according to any one of claims 1 to 4, characterized in that: The coupling mechanism further comprises a first adjustment mechanism for adjusting the positioning of the distance measuring device relative to the laser welding tool.

8. The distance measurement system according to any one of claims 1 to 4, characterized in that: The ranging system also includes a control system that uses the ranging distance to calculate a welding distance to a focal point of the laser welding beam.

9. The distance measurement system according to claim 8, characterized in that: The control system determines whether the weld distance is within a predetermined tolerance.

10. The distance measurement system according to claim 9, characterized in that: The control system outputs an indication of whether the weld distance is within the predetermined tolerance.

11. A laser welding system, characterized in that: The laser welding system comprises: a laser welding tool for welding workpieces at a welding location by emitting a welding beam along a beam path; and A ranging system, the ranging system comprising: a ranging device designed and configured to determine a ranging distance to the weld location when the ranging system is used during a welding operation; and A coupling mechanism designed and configured to couple the distance measuring device in a fixed relationship relative to the laser welding tool so that: When the ranging device determines the ranging distance, at least a portion of the ranging device is located at a ranging position in the beam path; and When the laser welding tool emits the welding beam to perform the welding, the distance measuring device is located at a welding position outside the beam path.

12. The laser welding system according to claim 11, characterized in that: The coupling mechanism includes a reciprocating mechanism operably coupled to the ranging device and configured to reciprocate the ranging device between the welding position and the ranging position.

13. The laser welding system according to claim 12, characterized in that: The coupling mechanism comprises a support for fixedly fixing the coupling mechanism to the laser welding tool, and the reciprocating mechanism comprises: one or more guide rails fixedly secured to the support; and a reciprocating member slidably engaged with the one or more rails, the distance measuring device being fixedly mounted to the reciprocating member; The one or more guide rails and the reciprocating member are designed and configured so that the reciprocating member can reciprocate along the one or more guide rails, thereby moving the distance measuring device between the welding position and the distance measuring position.

14. The laser welding system according to claim 12, characterized in that: The reciprocating mechanism includes an axis of rotation about which the ranging device pivots as the ranging device moves between the welding position and the ranging position.

15. The laser welding system according to claim 13, characterized in that: The reciprocating mechanism includes an actuator coupled to the ranging device to reciprocate the ranging device between the welding position and the ranging position.

16. The laser welding system according to claim 15, characterized in that: The laser welding system also includes a control system in operative communication with the actuator to cause the actuator to move the shuttle to move the ranging device between the welding position and the ranging position.

17. The laser welding system according to any one of claims 11 to 14, characterized in that: The coupling mechanism further comprises a first adjustment mechanism for adjusting the positioning of the distance measuring device relative to the laser welding tool.

18. The laser welding system according to any one of claims 11 to 14, characterized in that: The laser welding system also includes a control system that uses the ranging distance to calculate a welding distance to a focal point of the laser welding beam.

19. The laser welding system according to claim 18, characterized in that: The control system determines whether the weld distance is within a predetermined positioning tolerance.

20. The laser welding system according to claim 19, characterized in that The control system outputs an indication of whether the weld distance is within the predetermined positioning tolerance.

21. The laser welding system according to claim 19, characterized in that The laser welding system further includes at least one actuator for adjusting the welding distance, wherein the control system controls the at least one actuator so that the welding distance is within the predetermined positioning tolerance.

Images