Hand-held laser welding torch
By introducing a monitoring module and control board into the handheld laser welding gun, the plasma spectrum signal is monitored in real time, and the laser focusing spot is dynamically adjusted. This solves the problems of material damage and operator injury when the laser deviates from the metal surface, and achieves high-precision welding and safety protection.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- TERMMEI TORCH & TIP CO
- Filing Date
- 2025-04-22
- Publication Date
- 2026-06-02
AI Technical Summary
Existing handheld laser welding guns lack an effective real-time monitoring mechanism for the laser's position, which means that the output cannot be stopped in time when the laser deviates from the metal surface, posing a risk of material damage and accidental injury to the operator. Furthermore, traditional detection methods have slow response and poor anti-interference capabilities, making it difficult to meet the requirements of high-precision welding.
The system employs a monitoring module to capture spectral signals of specific bands of plasma and controls the laser output in real time via a control board. Combined with a galvanometer motor to dynamically adjust the laser focusing spot, it integrates multiple safety protection mechanisms, including interlock switches and automatic locking mechanisms, to ensure that the laser is emitted only during effective welding.
It enables real-time position monitoring and safety control of the laser welding torch, preventing the laser from accidentally hitting non-metallic surfaces or the human body, ensuring stable and reliable welding quality, and improving operational safety and welding accuracy.
Smart Images
Figure CN224309822U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of laser welding technology, and in particular relates to a handheld laser welding gun. Background Technology
[0002] With the widespread application of laser welding technology, handheld laser welding guns are increasingly being adopted by various industries for metal processing, repair, and manufacturing. While existing handheld laser welding guns offer portability and flexibility, they face two major technical bottlenecks in practical applications:
[0003] First: There is a lack of an effective real-time monitoring mechanism for the laser's position. When the laser deviates from the metal surface (such as during dry burning or focal length shift), the laser output cannot be terminated in time, which can easily cause material damage or accidental injury to the operator.
[0004] Secondly, traditional welding torches rely on indirect detection methods such as mechanical limit switches or infrared sensors, which have problems such as slow response and poor anti-interference ability, making it difficult to meet the needs of high-precision welding scenarios.
[0005] Therefore, how to avoid the above-mentioned drawbacks is a technical problem that urgently needs to be solved in this field.
[0006] It should be noted that the information disclosed in this background section is only for understanding the background technology of this application concept, and therefore, the above description is not considered to constitute information related to the technology. Utility Model Content
[0007] This disclosure provides at least one handheld laser welding gun.
[0008] In a first aspect, embodiments of this disclosure provide a handheld laser welding gun, comprising:
[0009] Welding torch body;
[0010] The monitoring module, which is located inside the welding torch, is used to capture spectral signals of specific wavelengths of plasma.
[0011] The control board, located inside the welding torch, is used to control whether the welding torch emits laser light outwards.
[0012] The control module is electrically connected to the monitoring module and the control board, respectively, and is configured to control the monitoring module to capture the spectral signal of a specific band of plasma after the welding torch body emits a laser.
[0013] When the detection time of the monitoring module exceeds the specified duration and fails to reach the preset spectral intensity or threshold, the control board is adapted to cut off the laser output.
[0014] In one optional implementation, the monitoring module includes a monitoring probe and a signal processor, wherein the monitoring probe is disposed on the top wall of the welding torch body and faces the nozzle of the welding torch body;
[0015] The signal processor is electrically connected to the monitoring probe and the control board;
[0016] The monitoring probe transmits the captured spectral signal to the signal processor, which is adapted to determine whether the characteristic spectrum generated by the plasma reaches a preset spectral intensity or a preset threshold.
[0017] In one optional embodiment, the monitoring probe includes a bandpass filter with a passband range of 200-2000 nm and a center wavelength corresponding to the characteristic emission spectrum of the metal plasma.
[0018] In one optional embodiment, a connecting rod is provided between the welding torch body and the nozzle, the connecting rod being made of stainless steel and the nozzle being made of brass.
[0019] In one alternative embodiment, a spatter deflector is provided inside the connecting rod, the spatter deflector being adapted to block large particles of spatter from hitting the protective mirror inside the welding torch body.
[0020] In one alternative embodiment, the inner wall of the nozzle is conical;
[0021] The inner diameter of the splash baffle is smaller than the maximum outer diameter of the nozzle conical inner wall.
[0022] In one optional embodiment, a galvanometer motor is provided inside the welding torch body, and the galvanometer motor is adapted to drive a reflecting mirror.
[0023] The nozzle and galvanometer motors are electrically connected to the main control board inside the welding torch body;
[0024] When the nozzle comes into contact with the workpiece to be welded, the main control board controls the galvanometer motor to swing and dynamically adjust the size of the laser focusing spot on the reflector to ensure that the laser energy density is always at the optimal threshold for metal melting.
[0025] In one alternative embodiment, the welding torch body includes an interlock switch disposed near the light emission button on the welding torch body.
[0026] In one alternative implementation, the interlock switch includes an automatic locking mechanism for disabling wire filling, unlocking the welding torch, and turning on the lighting.
[0027] The beneficial effects of this invention are that it provides a handheld laser welding torch, which, through the cooperation of a monitoring module and a control board, achieves real-time control after laser emission, ensuring that the laser is only emitted during effective welding and preventing accidental laser impact on non-metallic surfaces or harm to the human body. The system also integrates multiple safety protection mechanisms to ensure personnel safety during operation. By setting up the monitoring module, the plasma spectral signal during laser emission is monitored in real time, ensuring stable and reliable welding quality.
[0028] Other features and advantages of this invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objectives and other advantages of this invention are realized and obtained through the structures particularly pointed out in the description and the accompanying drawings.
[0029] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description
[0030] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of this utility model, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0031] Figure 1 A perspective view of a handheld laser welding gun provided in an embodiment of this disclosure;
[0032] Figure 2 An internal perspective view of the welding torch body provided in an embodiment of this disclosure;
[0033] Figure 3 This is a longitudinal sectional front view of the welding torch body provided in an embodiment of this disclosure;
[0034] Figure 4 This is a schematic diagram of the monitoring module and control board provided in the embodiments of this disclosure.
[0035] In the picture:
[0036] 1. Welding torch body; 11. Connecting rod; 12. Nozzle; 13. Spatter deflector; 14. Galvanometer motor; 15. Reflecting mirror; 16. Light emission button;
[0037] 2. Monitoring module; 21. Monitoring probe; 22. Signal processor; 23. Bandpass filter;
[0038] 3. Control board; 4. Control module; 42. Interlock switch. Detailed Implementation
[0039] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0040] In this document, when it is mentioned that a first component is located on a second component, this can mean that the first component can be directly formed on the second component, or that a third component can be inserted between the first and second components. Furthermore, in the accompanying drawings, the thickness of the components may be exaggerated or reduced for the purpose of effectively describing the technical content.
[0041] In this document, exemplary embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings. As used herein, expressions such as “at least one of…” modify the entire list of elements when following a list of elements, rather than individual elements in the list. For example, the expression “at least one of a, b, and c” should be understood to include only a, only b, only c, both a and b, both a and c, both b and c, or all of a, b, and c.
[0042] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless otherwise clearly stated herein. The terms “comprising,” “including,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.
[0043] As used herein, the phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally refer to the fact that a particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of this disclosure. Therefore, a particular feature, structure, or characteristic can be included in more than one embodiment of this disclosure, such that these phrases do not necessarily refer to the same embodiment. As used herein, the terms “example,” “exemplary,” etc., are used to “serve as an example, instance, or illustration.” Any implementation, aspect, or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or superior to other implementations, aspects, or designs. Rather, the use of the terms “example,” “exemplary,” etc., is intended to present concepts in a specific manner.
[0044] Research has revealed that, with the widespread application of laser welding technology, handheld laser welding guns are increasingly being adopted by various industries for metal processing, repair, and manufacturing. While existing handheld laser welding guns offer portability and flexibility, they face two major technical bottlenecks in practical applications:
[0045] First: There is a lack of an effective real-time monitoring mechanism for the laser's position. When the laser deviates from the metal surface (such as during dry burning or focal length shift), the laser output cannot be terminated in time, which can easily cause material damage or accidental injury to the operator.
[0046] Secondly, traditional welding torches rely on indirect detection methods such as mechanical limit switches or infrared sensors, which have problems such as slow response and poor anti-interference ability, making it difficult to meet the needs of high-precision welding scenarios.
[0047] Therefore, how to avoid the above-mentioned drawbacks is a technical problem that urgently needs to be solved in this field.
[0048] The defects in the above solutions and the reasons for their occurrence are the results of the inventors' practice and careful research. Therefore, the discovery process of the above problems and the solutions proposed in this disclosure should be considered as the inventors' contributions to this disclosure.
[0049] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0050] The following detailed description, with reference to the accompanying drawings, describes some embodiments of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.
[0051] like Figures 1 to 4As shown, at least one embodiment provides a handheld laser welding gun, including: a welding gun body 1; which is made of one-piece aluminum alloy material, which can minimize thermal resistance and improve heat dissipation performance under water-free conditions. Simultaneously, the gripping part of the welding gun body 1 is covered with a reinforcing shell, which not only increases friction during gripping but also reduces heat transfer to the operator. Preferably, the reinforcing shell can be a carbon fiber reinforced composite material, a ceramic-metal composite laminate, an engineering plastic-based composite material, or a special rubber-metal composite material. A monitoring module 2, which is disposed within the welding gun body 1, is used to capture the spectral signal of a specific wavelength band of plasma; the specific wavelength refers to the characteristic plasma spectrum generated during the welding of most metals in the 200-2000nm range, such as iron-based materials: Fe plasma has a significant characteristic spectral line near 521.8nm (green band). Copper-based materials: Cu plasma has a main peak at approximately 510-578nm (green-yellow band).
[0052] A control board 3, housed within the welding torch body 1, controls whether the welding torch body 1 emits laser light. A control module 4, electrically connected to both the monitoring module 2 and the control board 3, is configured to control the monitoring module 2 to capture the spectral signal of a specific wavelength band of the plasma after the welding torch body 1 emits laser light. When the detection time of the monitoring module 2 exceeds a specified duration and fails to reach a preset spectral intensity or threshold, the control board 3 is adapted to cut off the laser output. Through the cooperation of the monitoring module 2 and the control board 3, real-time control of the laser emission is achieved, ensuring that the laser is only emitted during effective welding, preventing accidental laser impact on non-metallic surfaces or harm to the human body. The system also integrates multiple safety protection mechanisms to ensure personnel safety during operation. The monitoring module 2 monitors the plasma spectral signal during laser emission in real time, ensuring stable and reliable welding quality.
[0053] Reference Appendix Figure 3The monitoring module 2 includes a monitoring probe 21 and a signal processor 22. The monitoring probe 21 is installed on the top wall inside the welding torch body 1 and faces the nozzle 12 of the welding torch body 1. The monitoring probe 21 is built into the welding torch body 1 and directly faces the nozzle 12 area. The optical path is coaxial with the laser and the included angle is ≤5°, ensuring real-time signal acquisition. The signal processor 22 is electrically connected to the monitoring probe 21 and the control board 3. The monitoring probe 21 transmits the captured spectral signal to the signal processor 22, which is suitable for determining whether the characteristic spectrum generated by the plasma reaches a preset spectral intensity or a preset threshold. Through the cooperation of the monitoring probe 21 and the signal processor 22, it is ensured that the laser will not be emitted unexpectedly during use. If it is detected that the laser does not hit the metal surface, or the distance between the welding torch body 1 and the workpiece is not within the appropriate range, the signal processor 22 transmits the signal to the control module 4. The control module 4 controls the control board 3 to cut off the laser emission of the welding torch body 1, thereby avoiding laser scattering or harm to the human body.
[0054] Reference Appendix Figure 3 The monitoring probe 21 includes a bandpass filter 23 with a passband range of 200-2000 nm, and its center wavelength corresponds to the characteristic emission spectrum of metal plasma. When welding aluminum alloy, the center wavelength of the bandpass filter 23 is set to 396.15 nm, and the reflector 15 can be focused to a spot diameter of 0.3-0.6 mm. The operator presses the light output button 16, and the laser is focused and emitted by the emitting crystal. The monitoring probe 21 collects the plasma spectrum, and the signal processor 22 calculates the peak intensity at 396.15 nm. If the intensity is >1500 W / cm² / nm, the laser output is maintained; otherwise, gradient protection is triggered. The galvanometer motor 14 adjusts the angle of the reflector 15 to compensate for focus shift. When welding a stainless steel back plate, the bandpass filter 23 is adjusted to 521.8 nm, for Fe plasma.
[0055] Reference Appendix Figure 2 The welding torch body 1 includes an interlock switch 42, which is located near the light output button 16 and is used to disable wire feeding, unlock the welding torch, and turn on the illumination. The interlock switch 42 includes an automatic locking mechanism. The control signal line of the interlock switch 42 is directly connected to the MOSFET gate of the laser drive power supply within the welding torch body, ensuring a power-off response time of <10ms. When the interlock switch 42 is triggered, it locks the light output button 16 until manually reset. In this embodiment, the trigger signal of the interlock switch 42 has the highest interrupt priority, immediately terminating laser output even if the light output button 16 is pressed.
[0056] Continue to refer to the appendix Figure 2The automatic locking mechanism of the interlock switch 42 implements a gradient protection strategy: Level 1 protection: if the plasma signal is lost for 0.5 seconds, the laser power is reduced to 30%; Level 2 protection: if the signal is lost for 1 second, the laser output is completely cut off and an audible and visual alarm is activated.
[0057] Continue to refer to the appendix Figure 3 A connecting rod 11 is provided between the welding torch body 1 and the nozzle 12. The connecting rod 11 is made of stainless steel, and the nozzle 12 is made of brass. A spatter baffle 13 is provided inside the connecting rod 11. The spatter baffle 13 is adapted to prevent large particles from splashing and hitting the protective mirror inside the welding torch body 1. The spatter baffle 13 can prevent large particles from impacting the protective mirror through the connecting rod 11. The protective mirror is located inside the welding torch body 1 near the connecting rod 11 to prevent particles from splashing into the welding torch body 1 during the welding process. The inner wall of the nozzle 12 is conical; the inner diameter of the spatter baffle 13 is smaller than the maximum outer diameter of the conical inner wall of the nozzle.
[0058] Reference Appendix Figure 3 A galvanometer motor 14 is installed inside the welding torch body 1, located at the inner end of the welding torch body 1 away from the connecting rod 11. A reflector 15 is positioned on the laser path within the welding torch body 1, close to the galvanometer motor 14. The galvanometer motor 14 is adapted to drive the reflector 15. The nozzle 12 and the galvanometer motor 14 are electrically connected to the main control board within the welding torch body 1. When the nozzle 12 contacts the workpiece, the main control board controls the galvanometer motor 14 to swing, dynamically adjusting the laser focusing spot size on the reflector 15 to ensure the laser energy density remains at the optimal threshold for metal melting. Spot size control: Based on feedback from the nozzle 12 indicating contact with the workpiece, the galvanometer motor 14 drives the reflector 15 to deflect at a frequency of 200Hz (range ±5°), dynamically adjusting the laser spot diameter within the range of 0.2-0.8mm to ensure the energy density remains stable at the optimal threshold for metal melting (10). 6 ~10 7 W / cm²). Focus compensation algorithm: Built-in PID controller, when welding torch vibration is detected (acceleration > 2m / s²), the galvanometer compensates for focus shift within 10ms (error < ±0.05mm). When monitoring module 2 detects a 20% decrease in plasma signal intensity, reflector 15 automatically reduces the spot diameter by 10% to improve local energy density.
[0059] In the description of the embodiments of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0060] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence unless expressly indicated herein. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or segment discussed above may be referred to as the second element, component, region, layer, or segment.
[0061] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.
Claims
1. A handheld laser welding gun, characterized in that, include: Welding torch body (1); The monitoring module (2) is installed inside the welding torch body (1) and is used to capture the spectral signal of the plasma band. The control board (3) is located inside the welding torch body (1) and is used to control whether the welding torch body (1) emits laser light outward. The control module (4) is electrically connected to the monitoring module (2) and the control board (3) respectively, and is configured as follows: After the welding torch body (1) emits a laser, the monitoring module (2) is controlled to capture the spectral signal of the plasma band. When the detection time of the monitoring module (2) exceeds the specified duration and fails to reach the preset spectral intensity or threshold, a cut-off command is sent to the control board (3); The control board (3) cuts off the laser output in response to the cut-off command.
2. The handheld laser welding gun as described in claim 1, characterized in that, The monitoring module (2) includes a monitoring probe (21) and a signal processor (22). The monitoring probe (21) is disposed on the inner top wall of the welding torch body (1) and faces the nozzle (12) of the welding torch body (1). The signal processor (22) is electrically connected to the monitoring probe (21) and the control board (3); The monitoring probe (21) transmits the captured spectral signal to the signal processor (22), which is adapted to determine whether the characteristic spectrum generated by the plasma reaches a preset spectral intensity or a preset threshold.
3. The handheld laser welding gun as described in claim 2, characterized in that, The monitoring probe (21) includes a bandpass filter (23) with a passband range of 200-2000nm and a center wavelength corresponding to the characteristic emission spectrum of the metal plasma.
4. The handheld laser welding gun as described in claim 1, characterized in that, A connecting rod (11) is provided between the welding torch body (1) and the nozzle (12). The connecting rod (11) is made of stainless steel, and the nozzle (12) is made of brass.
5. The handheld laser welding gun as described in claim 4, characterized in that, A spatter baffle (13) is provided inside the connecting rod (11), which is suitable for blocking large particles of spatter from hitting the protective mirror inside the welding torch body (1).
6. The handheld laser welding gun as described in claim 5, characterized in that, The inner wall of the nozzle (12) is conical; The inner diameter of the splash baffle (13) is smaller than the maximum outer diameter of the conical inner wall of the nozzle (12).
7. The handheld laser welding gun as described in claim 6, characterized in that, A galvanometer motor (14) is provided inside the welding torch body (1), and the galvanometer motor (14) is adapted to drive the reflecting mirror (15). The nozzle (12) and the galvanometer motor (14) are electrically connected to the main control board inside the welding torch body (1); When the nozzle (12) comes into contact with the workpiece, the main control board controls the galvanometer motor (14) to swing and dynamically adjust the size of the laser focusing spot on the reflector (15) to ensure that the laser energy density is always at the optimal threshold for metal melting.
8. The handheld laser welding gun as described in claim 1, characterized in that, The welding torch body (1) includes an interlock switch (42), which is located on the welding torch body (1) near the light output button (16).
9. The handheld laser welding gun as described in claim 8, characterized in that, The interlock switch (42) includes an automatic locking mechanism for disabling wire filling, unlocking the welding torch, and turning on the lighting.