Handheld Laser Welding Equipment

Abstract

The laser welding system includes a laser power supply having a controller that controls activation of a laser light by the power supply. A sense lead is attachable to the workpiece. A handheld laser welding torch is connected to the power supply to receive the laser light. The torch includes a nozzle having an electrically insulating outer surface and a pressure sensor that measures a pressure level applied to the nozzle and generates a pressure level signal. A proximity sensor is operatively connected to the sense lead and the torch and configured to determine if the torch is adjacent to the workpiece and to generate a proximity signal. A controller receives the pressure level signal and the proximity signal. The controller activates the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the torch is adjacent to the workpiece.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 281,116, filed November 19, 2021, which is a continuation of U.S. Patent Application No. 17 / 974,711, filed October 27, 2022, the disclosures of which are incorporated herein by reference in their entireties.

[0002] FIELD OF THE DISCLOSURE Embodiments of the invention relate to laser devices, and more particularly, to handheld laser devices, systems, and methods for, for example, welding and cutting. [Background technology]

[0003] Handheld laser devices can be very effective in performing certain types of welding or cutting procedures on workpieces. However, when using such devices, the accidental emission of laser light into free space or otherwise in an undesired or unintended direction away from the workpiece is generally undesirable. Moreover, performance improvements in relation to certain aspects of handheld laser devices are desirable. Summary of the Invention [Means for solving the problem]

[0004] The following summary presents a simplified summary to provide a basic understanding of some aspects of the devices, systems, and / or methods disclosed herein. This summary is not an extensive overview of the devices, systems, and / or methods disclosed herein. It is not intended to identify key elements or to delineate the scope of such devices, systems, and / or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented below.

[0005] According to one aspect of the present invention, a laser welding system is provided. The laser welding system includes a laser power supply having a controller that controls activation of a laser light by the laser power supply. A sense lead is attachable to a workpiece to be welded. A handheld laser welding torch is operably connected to the laser power supply for receiving the laser light from the laser power supply. The handheld laser welding torch includes a nozzle having an electrically insulating outer surface and a pressure sensor that measures a pressure level applied to the nozzle and generates a corresponding pressure level signal. The laser welding system further includes a proximity sensor operably connected to the sense lead and the handheld laser welding torch and configured to determine if the handheld laser welding torch is adjacent to the workpiece and to generate a corresponding proximity signal. The controller receives the pressure level signal from the pressure sensor and the proximity signal from the proximity sensor. The controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece.

[0006] According to another aspect of the present invention, a laser welding system is provided. The laser welding system includes a laser power supply having a controller that controls activation of a laser light by the laser power supply. A sense lead is attachable to a workpiece to be welded. A handheld laser welding torch is operably connected to the laser power supply for receiving the laser light from the laser power supply. The handheld laser welding torch includes a nozzle and a pressure sensor that senses a pressure level applied to the nozzle and generates a corresponding pressure signal. The laser welding system further includes a proximity sensor operably connected to the sense lead and the handheld laser welding torch and configured to determine if the handheld laser welding torch is adjacent to the workpiece and to generate a corresponding proximity signal. The controller receives the pressure signal from the pressure sensor and receives the proximity signal from the proximity sensor. The controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece.

[0007] In accordance with another aspect of the present invention, a laser welding system is provided. The laser welding system includes a laser power supply having a controller that controls activation of a laser light by the laser power supply. A sense lead is attachable to a workpiece to be welded. A handheld laser welding torch is operatively connected to the laser power supply for receiving the laser light from the laser power supply. The handheld laser welding torch includes a nozzle and a pressure sensor that generates a pressure signal based on a pressure level applied to the nozzle. The laser welding system further includes means for determining when the handheld laser welding torch is adjacent to the workpiece to be welded and for generating a corresponding proximity signal. The controller receives the pressure signal from the pressure sensor and the proximity signal from the proximity sensor. The controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece.

[0008] These and other aspects of the present invention will become apparent to those skilled in the art to which the present invention pertains upon reference to the following description, which refers to the accompanying drawings, including the following figures: [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a system block diagram illustrating an embodiment of a laser welding system. [Diagram 2] A handheld laser welding torch is shown. [Diagram 3] 1 shows the user interface of the laser power supply. [Figure 4] 2 shows a block diagram of one exemplary embodiment of a controller that may be used, for example, in the laser welding system of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention relates to a handheld laser device for welding and cutting. The present invention will now be described with reference to the drawings in which like reference numerals are used to refer to like elements throughout. It should be understood that the various figures are not necessarily drawn to scale from one figure to another or within a given figure, and in particular, component sizes are arbitrarily drawn to facilitate comprehension of the figures. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the invention. However, it will be apparent that the invention may be practiced without these specific details. In addition, other embodiments of the invention are possible, and the invention is capable of being practiced and performed otherwise than as described. The terms and phrases used in the description of the present invention are used for the purpose of facilitating understanding of the invention and should not be construed as limiting.

[0011] As used herein, "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" each mean A only, B only, C only, A and B together, A and C together, B and C together, or A, B, and C together. Any disjunctive term or phrase presenting two or more alternative terms, whether contained in the description of the embodiments, claims, or drawings, should be understood as contemplating the possibility of including one of the terms, either of the terms, or both of the terms. For example, the phrase "A or B" should be understood to include the possibility of "A" or "B" or "A and B."

[0012] Although the embodiments of the invention described herein are described in the context of laser welding, other embodiments of the invention are not so limited. For example, embodiments may be utilized in laser cutting operations. As used herein, the terms "welding" or "laser welding" are intended to encompass both laser welding and cutting. In the interest of efficiency, the term "welding" is used below in the description of exemplary embodiments, but this should be interpreted as including both welding and cutting.

[0013] FIG. 1 is a system block diagram illustrating one embodiment of a laser welding and cutting system 100 (hereinafter referred to as the laser welding system for ease of explanation). The laser welding system 100 includes a handheld laser welding / cutting torch 130 or gun and is configured for manual operation by an operator. The laser welding system 100 includes, among other things, a laser power supply 110 having a laser generator 112, a controller 114, and a user interface 116. The controller 114 is operatively connected to the laser generator 112 for controlling the activation of a laser light 118 by the laser power supply 110. The controller 114 is also operatively connected to the user interface 116. The user interface 116 allows an operator to set and observe various operating parameters of the laser power supply 110. The structure and operation of the laser power supply is known in the art and need not be described in detail herein.

[0014] In certain embodiments, the laser welding system 100 also includes a wire feeder 120. The wire feeder 120 supplies a consumable wire 122 to the torch 130. The consumable wire 122 may function as a filler wire that is melted by laser energy during welding. In certain embodiments, the consumable wire 122 may be a so-called hot wire that is preheated by the wire feeder 120 or the torch 130 before discharge from the torch toward a welding zone on the workpiece W. The preheated consumable wire 122 is subsequently melted by the laser beam 118. When an electric arc is generated between the heated consumable wire 122 and the workpiece W, the laser beam 118 may be automatically disabled. Similarly, the hot wire power supply and the wire feeder 120 may be disabled when the torch 130 is removed from the workpiece W.

[0015] The handheld laser welding torch 130 is operatively connected to the laser power supply 110 to receive laser light 118 from the laser power supply. The torch 130 may include laser optics to direct and / or focus the laser light from the laser power supply 110 toward the weld zone. The laser welding system 100 may further include a welding work clamp 140 and sense leads 142, a cylinder of shielding gas 150, a protective helmet 160, and a laser shielding glass 170 configured to be worn under the protective helmet 160. Laser energy (e.g., laser light 118) is provided from the laser power supply 110 to the torch 130 via a wire feeder 120, according to one embodiment. Alternatively, laser energy is provided from the laser power supply 110 directly to the torch 130 via suitable optical wiring. Although various aspects are described herein in terms of laser welding, applications to laser cutting are similarly valid.

[0016] FIG. 2 shows the handheld laser welding torch 130 in more detail. The torch 130 may include a trigger 132 for activating and deactivating the laser light during welding. In certain embodiments, the torch 130 may include a laser light guard 134 that blocks reflected laser light (e.g., reflected from a workpiece during welding). The laser light guard 134 may be attached at a distal end of the torch 130, such as near the nozzle 136 of the torch. In certain embodiments, the laser light guard 134 may attenuate or filter laser reflections while allowing an operator to view the weld zone through the laser light guard, such as through a lens on the guard. The laser light guard 134 may help protect the operator's eyes from laser reflections during welding / cutting. A protective helmet 160 and / or laser shielding glasses 170 may provide additional eye protection for the operator. If desired, the laser welding system 100 can include a barrier / curtain around the welding work area to provide additional protection from the laser light 118 emitted from the torch 130.

[0017] The laser welding system 100 may include various features to help ensure activation of the laser light 118 only when the torch 130 is located near or adjacent to or directed at the workpiece W. Such features may prevent accidental emission of the laser light into free space or in an otherwise undesirable or unintended direction (e.g., toward the operator or toward bystanders). In one embodiment, the outer surface of the nozzle 136 of the torch 130 is electrically insulating. The nozzle 136 could be made of a non-conductive material (not electrically conductive), such as, for example, ceramic, or could have an electrically insulating coating. The laser welding system 100 may include a sense lead 142 from the laser power supply 110. The sense lead 142 has a work clamp 140 at its distal end. The work clamp 140 may be used to attach the sense lead from the laser power supply 110 to the workpiece W. The work clamp 140 may include a jaw or bolt arrangement to clamp to the workpiece W. The laser welding system 100 may also include a proximity sensor 138 operatively connected to the sense leads 142 and the handheld laser welding torch 130. The proximity sensor 138 is configured to determine if the torch 130 is adjacent to the workpiece W and to generate a corresponding proximity signal such that the laser light is not activated while the torch is located a predetermined distance from the workpiece. The proximity signal is transmitted to a controller 114 in the laser power supply 110 such that the controller knows when the torch 130 is located near or adjacent to the workpiece. Exemplary types of proximity sensors may include, without limitation, magnetic proximity sensors, inductive proximity sensors, capacitive proximity sensors, and the like. The proximity sensor 138 is shown in FIG. 2 diagrammatically as being located within or on top of the torch 130. The proximity sensor 138 is intended to function in conjunction with the sense leads 142 and the work clamp 140 to determine if the torch 130 is adjacent to the workpiece W.For example, the work clamp 140 must be attached to the workpiece W in order for the proximity sensor 138 to detect that the torch 130 is adjacent to the workpiece. An electrically insulating material or outer surface of the nozzle 136 may prevent the work clamp 140 from being directly connected to the nozzle to defeat the system's ability to detect the proximity of the torch 130 to the workpiece W. A ceramic or other electrically insulating cover on the nozzle 136 may prevent the sense lead 142 / work clamp 140 from being directly connected to the torch 130 instead of the workpiece W and may also prevent the nozzle from overheating. In certain embodiments, the sense lead 142 may include a magnet at its distal end rather than a work clamp to attach the sense lead to the workpiece W. In this case, the nozzle 136 can be manufactured from a non-magnetic material (e.g., aluminum, brass, ceramic, certain stainless steels, etc.) so that the magnet from the sense lead 142 cannot be attached to the nozzle 136 to defeat the system's ability to detect the proximity of the torch 130 to the workpiece W.

[0018] In certain embodiments, the torch 130 may include a pressure sensor 139 to allow the torch to operate with a pressure contact nozzle, similar to the nose of a nail gun, such that the laser light 118 is not activated unless an operator presses the nozzle 136 against the workpiece W. The pressure sensor 139 may detect, measure, or otherwise respond to an axial pressure level applied to the nozzle 136 and generate a corresponding pressure or pressure level signal based on the axial pressure applied to the nozzle by the workpiece. In one example embodiment, the pressure sensor 139 includes a strain gauge for measuring the pressure applied to the nozzle 136. In another example embodiment, the pressure sensor 139 includes a switch that is actuated (e.g., closed or open) when the axial pressure level applied to the nozzle 136 meets or exceeds a threshold level. Those skilled in the art will appreciate that other types of pressure sensors that may be used to provide the torch 130 with functionality similar to the nose of a nail gun, such as, for example, piezoelectric or capacitive pressure sensors, solid state sensors, optical sensors, or MEMS devices.

[0019] Both the pressure or pressure level signal from the pressure sensor 139 and the proximity signal from the proximity sensor 138 are sent to a controller 114 in the laser power supply 110. The controller 114 receives these signals to determine whether the torch 130 is located near or adjacent to the workpiece W and is pressed against the workpiece. The controller 114 is configured to activate the laser beam 118 when the pressure level applied to the nozzle 136 meets or exceeds a threshold pressure level and the proximity signal indicates that the torch 130 is adjacent to the workpiece. A further condition for activating the laser beam 118 may be the pulling of a trigger 132 on the torch 130. However, in certain embodiments, pulling the trigger 132 is not required to activate the laser beam 118, and only the pressing of the nozzle 136 against the workpiece W by a sense lead 142 attached to the workpiece will cause the controller 114 to activate the laser beam. The controller 114 can compare the pressure level signal from the pressure sensor 139 to a stored threshold pressure level to determine whether the torch 130 is pressed against the workpiece W. Alternatively, the comparison can be performed mechanically via a biasing mechanism within the torch 130. For example, pressing the nozzle 136 against the workpiece W with sufficient force to meet or exceed the threshold can activate a switch within the torch 130, which then generates a pressure level signal. In this case, the controller 114 need not compare the pressure level signal to a stored threshold value, since the presence of the pressure level signal will signal that sufficient pressure has been applied to the nozzle 136. The controller 114 can also compare the proximity signal from the proximity sensor 138 to a stored threshold proximity level to determine whether the torch 130 is adjacent to the workpiece W.

[0020] In certain embodiments, the laser power supply 110 may include a software lockout that prevents unauthorized personnel from operating the laser torch 130. In one embodiment, an operator must first attend and pass a safety training class, and then receive an operator code that the operator uses to activate the laser welding system 100. The operator does not receive the operator code until such time as the operator passes the safety training class. The code may be provided in one of any number of different ways (e.g., in a text message, in an email, encoded on an RFID tag, or as an encoded badge, etc.). The user interface 116 of the laser power supply may be configured to receive input of the operator code, such as by scanning an RFID tag or QR code associated with the operator, or by receiving manual entry of the code by the operator (e.g., manual entry of an alphanumeric code). The controller 114 verifies the operator code and enables activation of the laser light only after the operator code is verified.

[0021] As can be seen in FIG. 3, in certain embodiments, the user interface 116 can be configured to display a checklist. The controller 114 verifies acknowledgement inputs from the operator corresponding to each element of the checklist, and enables activation of the laser light only after the acknowledgement inputs are verified. In FIG. 3, an example checklist displayed on the user interface 116 has three elements (checklist items A, B, and C), the first two of which have received acknowledgement inputs. The elements of the checklist can correspond to steps or actions that the operator must take before performing laser welding. In one embodiment, an entire safety kit is provided that can be set up to provide various safety features around the laser welding work area. The safety kit can include, for example, safety PPE, barriers, and sensors. The checklist displayed on the user interface 116 can be provided such that the operator must view and acknowledge each item in the checklist (e.g., by pressing a button against a touch-sensitive display area) before the laser welding operation can proceed. The checklist may require, for example, that the operator acknowledges that laser safety PPE (e.g., laser safety glasses (or equivalent), laser safety gloves) is properly worn and that a laser safety officer is present. In one embodiment, the checklist may require that an anti-reflective coating be applied to the workpiece. The anti-reflective coating is applied as a liquid on the workpiece and dried before welding begins. The anti-reflective coating reduces reflection of infrared energy (generated by the laser beam) from the workpiece. Similarly, the checklist may require the use of an anti-reflective shielding gas (e.g., water vapor, CO2). The anti-reflective shielding gas reduces reflection of infrared energy (generated by the laser beam) at or near the weld puddle.

[0022] In some embodiments of the laser welding system, the system may include an area scanner that scans for RFID tags around the welding area to ensure safety from reflected laser energy. For example, if a person enters an area where laser welding is occurring, the scanner of the laser welding system will detect an RFID tag worn by the person and will shut down the laser of the laser welding device. In one such embodiment, persons with access to the laser welding facility are required to wear such an RFID tag as part of the safety process. In certain embodiments, the laser welding system 100 may include a non-operator proximity sensor to keep non-laser operators away from the active laser. This may be accomplished by having a video surveillance system detect any human beings in the welding area. When a non-laser operator is detected in or near the welding area, the laser light may be automatically shut down (e.g., via wireless communication between the video surveillance system and the laser power supply 110). Other surveillance systems, including, for example, thermal, contact-detection, or RFID surveillance systems, may be utilized in a similar manner according to other embodiments.

[0023] In some embodiments, the helmet 160 can detect the presence of laser light. Reflection of laser light (laser energy) can cause damage to the user's head and eyes during the laser welding process. A sensor capable of detecting laser energy can be built into the user's protective welding helmet 160 (e.g., on the inside of the helmet, also with a laser light filter). The welding helmet 160 is further configured to communicate with the laser power supply 110 or the torch 130. In one embodiment, when a sensor in the welding helmet 160 detects laser energy during the laser welding process, a signal is sent to the laser power supply 110 (e.g., controller 114) or the torch 130 and shuts down the laser. An error symbol or text can be presented on the display of the welding helmet 160 or of the laser power supply 110 to notify the user of the problem. If the laser light enters the interior of the helmet 160, such as around the neck area of ​​the helmet, the laser light sensor in the helmet can shut off the laser light. The laser welding system 100 can also include at least one sensor configured to detect laser energy generated directly outside the work area and can shut down the laser welding system accordingly for safety reasons.

[0024] In one embodiment, the laser beam of the torch 130 is used to track the weld joint, and if the laser beam moves out of the weld joint, the system can shut down the laser beam and / or provide a warning to the user.

[0025] In certain embodiments, the torch 130 may include one or more light emitting diodes (LEDs) to illuminate the weld puddle during the welding operation to improve the visibility of the weld and the weld puddle to the user. The torch 130 may also include an emergency stop (E-Stop) device to disable the laser, especially if the torch lacks a trigger to activate the laser light. In one embodiment, a visible (e.g., red) laser guide light in the torch 130 is initially activated when the trigger 132 is pulled to the first trigger position. The guide light is turned off when the laser is activated with the trigger 132 being pulled to the second trigger position. The red laser guide light may be used to aid in identifying and aligning the tip of the handheld laser device with the joint on the workpiece to be welded. The use of a visible laser or LED to illuminate the weld puddle or to constantly illuminate the actual direction of the weld in relation to the joint during welding may also be incorporated in the torch 130.

[0026] In certain embodiments, the torch 130 can include mirrors to oscillate the laser beam and provide a relatively wide and / or adjustable weld puddle. Adjustable oscillation settings can be provided on the torch 130 via appropriate controls. Alternatively, the laser beam can be defocused to provide a relatively wide laser beam. The torch 130 can also include different interchangeable nozzle types and sizes to correspond to different types of welds to be formed.

[0027] One embodiment of a handheld laser welding system includes an angle monitor and vision system to ensure that the handheld laser device is used safely. For example, the angle monitor is programmed or "taught" (e.g., via a dry run of welding using a handheld laser welding torch with the laser off) the proper angle and position of the handheld laser device for a particular application to ensure safety. In one embodiment, a vision system (with a camera, etc.) is used to ensure proper use of the handheld laser device by the user. The laser is shut off if the handheld laser device deviates (within some tolerance) from the position for a particular welding procedure (e.g., via position monitoring using a camera or inertial sensor).

[0028] In one embodiment, the torch 130 includes an optical port mount that allows a digital camera to be attached to the optics of the laser, thereby allowing a user to better view the weld puddle area without having to weld in close proximity. The torch 130 further includes a display device operably connected to the digital camera to allow a user to view images (e.g., video) captured by the digital camera. As a result, the user does not have to be too close to the weld puddle area to view what is occurring. In a further embodiment, the torch 130 includes a camera mounted at the front or distal end of the torch that functions as a laser viewfinder so that the weld puddle can be viewed. The torch 130 further includes a display device operably connected to the camera to allow a user to view images (e.g., video) captured by the camera.

[0029] In one embodiment, vision detection and RFID technology is used to detect the position of the operator's head during welding. The position can be compared to the laser line of sight and / or angle of the laser light reflection associated with the use of a handheld laser device. When the comparison indicates a potential danger to the operator, a warning can be provided and / or the laser can be shut down. Also provided in one embodiment is a non-operator proximity sensor having a camera that is aligned with the line of sight of the handheld welding gun during welding. The laser is shut down when a non-operator comes within the line of sight. Additionally, the operator and others in the area may be monitored for personal protective equipment (PPE), and the laser can be shut down and an alarm can be activated when someone is not complying with PPE regulations.

[0030] In one embodiment, a welding helmet 160 is provided with augmented reality (AR) capabilities that display an AR symbol on the welding helmet's head-up display (HUD) to indicate the location of the weld joint. A separate system can also be provided that actually finds / tracks the weld joint and communicates with the welding helmet to display the AR symbol in the appropriate location within the field of view. For example, in one embodiment, a laser from the torch 130 tracks the weld joint and the torch communicates the tracking information to the welding helmet 160. For example, in another embodiment, the angle monitor is programmed or "taught" (e.g., via a dry run of welding with the laser welding torch 130 with the laser off) the path of the weld joint that the helmet 160 uses to display the location of the weld joint via AR.

[0031] FIG. 4 illustrates a block diagram of an example embodiment of a controller 114 that may be used, for example, in the handheld laser welding system 100 of FIG. 1. For example, the controller 114 may be located within the laser power supply 110 as illustrated in FIG. 1. Referring to FIG. 4, the controller 114 includes at least one processor 314 (e.g., microprocessor, central processing unit, graphics processing unit) in communication with several peripheral devices via a bus subsystem 312. These peripheral devices may include, for example, a storage subsystem 324 including a memory subsystem 328 and a file storage subsystem 326, a user interface input device 322, a user interface output device 320, and a network interface subsystem 316. The input and output devices allow user interaction with the controller 114 and correspond to the user interface 116 illustrated in FIG. 1. The network interface subsystem 316 provides an interface to an outside network and is coupled to corresponding interface devices in other devices.

[0032] The user interface input devices 322 may include a keyboard, a pointing device such as a mouse, a trackball, a touchpad, or a graphics tablet, a scanner, a touch screen integrated into a display, a voice recognition system, an audio input device such as a microphone, and / or other types of input devices. In general, use of the term "input device" should be interpreted to include all possible types of devices and methods for inputting information into the controller 114 or onto a communications network.

[0033] The user interface output devices 320 may include a display subsystem, a printer, or a non-visual display, such as an audio output device. The display subsystem may include a flat panel device, such as a cathode ray tube (CRT), a liquid crystal display (LCD), a projection device, or some other mechanism for generating a visible image. The display subsystem may also provide a non-visual display, such as via an audio output device. In general, use of the term "output device" should be interpreted to include all possible types of devices and methods for outputting information from the controller 114 to a user or to another device or computer system.

[0034] The storage subsystem 324 stores programming and data structures that provide some or all of the functionality described herein. For example, computer-executable instructions and data are typically executed by the processor 314, alone or in combination with other processors. The memory 328 used within the storage subsystem 324 may include several memories, including a main random access memory (RAM) 330 for storing instructions and data during program execution, and a read-only memory (ROM) 332 in which fixed instructions are stored. The file storage subsystem 326 may provide persistent storage for program and data files, and may include a hard disk drive, a semiconductor device, a floppy disk drive with associated removable media, a CD-ROM drive, an optical drive, or a removable media cartridge. The computer-executable instructions and data that implement the functionality of certain embodiments may be stored by the file storage subsystem 326 within the storage subsystem 324, or in other devices accessible by one or more processors 314.

[0035] The bus subsystem 312 provides a mechanism for allowing the various components and subsystems of the controller 114 to communicate with each other as intended. Although the bus subsystem 312 is shown generally as a single bus, alternative embodiments of the bus subsystem may use multiple buses.

[0036] The controller 114 can be of a variety of types. Due to the ever-changing nature of computing devices and networks, the description of the controller 114 depicted in Figure 4 is intended only as a specific example for purposes of illustrating some embodiments. Many other configurations of controllers are possible having more or fewer components than the controller 114 depicted in Figure 4.

[0037] It will be apparent that the present disclosure is for illustrative purposes, and that various modifications may be made by adding, modifying, or removing details without departing from the fair scope of the teachings contained herein. Accordingly, the invention is not limited to the particular details of this disclosure, except to the extent that the appended claims are necessarily so limited.

Claims

1. 1. A laser welding system comprising: a laser power supply having a controller that controls activation of a laser beam by the laser power supply; a sense lead that can be attached to a workpiece to be welded; a handheld laser welding torch operatively connected to the laser power supply to receive the laser light from the laser power supply; 2. The handheld laser welding torch a nozzle having an electrically insulating outer surface; a pressure sensor that measures the pressure level applied to the nozzle and generates a corresponding pressure level signal; the laser welding system further includes a proximity sensor operably connected to the sense lead and the handheld laser welding torch and configured to determine whether the handheld laser welding torch is adjacent the workpiece and to generate a corresponding proximity signal; the controller receives the pressure level signal from the pressure sensor and the proximity signal from the proximity sensor, and the controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece. Laser welding system.

2. The laser welding system of claim 1 , further comprising a wire feeder that supplies consumable wire to the handheld laser welding torch.

3. The laser welding system of claim 1 , wherein the sense lead comprises a work clamp.

4. The laser welding system of claim 1 , wherein the pressure sensor comprises a strain gauge.

5. 2. The laser welding system of claim 1, wherein the pressure sensor includes a switch that activates when the pressure level applied to the nozzle meets or exceeds the threshold, and activation of the switch generates the corresponding pressure level signal.

6. 10. The laser welding system of claim 1, wherein the handheld laser welding torch includes a laser light guard that blocks reflected laser light.

7. 10. The laser welding system of claim 1, wherein the laser power supply further comprises a user interface operatively connected to the controller, the user interface configured to receive input of an operator code, and the controller configured to verify the operator code and enable activation of the laser light after the operator code is verified.

8. 8. The laser welding system of claim 7, wherein the user interface is configured to display a checklist, and the controller is configured to verify a plurality of acknowledge inputs corresponding to individual elements of the checklist and to enable activation of the laser light after the plurality of acknowledge inputs are verified.

9. 1. A laser welding system comprising: a laser power supply having a controller that controls activation of a laser beam by the laser power supply; a sense lead that can be attached to a workpiece to be welded; a handheld laser welding torch operatively connected to the laser power supply to receive the laser light from the laser power supply; 2. The handheld laser welding torch A nozzle; a pressure sensor that senses a pressure level applied to the nozzle and generates a corresponding pressure signal; the laser welding system further comprising a proximity sensor operatively connected to the sense lead and the handheld laser welding torch and configured to determine whether the handheld laser welding torch is adjacent the workpiece and to generate a corresponding proximity signal; the controller receives the pressure signal from the pressure sensor and the proximity signal from the proximity sensor, and the controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece. Laser welding system.

10. 10. The laser welding system of claim 9, further comprising a wire feeder that supplies consumable wire to the handheld laser welding torch.

11. 10. The laser welding system of claim 9, wherein the sense lead comprises a work clamp and the nozzle has an electrically insulating outer surface.

12. The laser welding system of claim 9 , wherein the sense lead includes a magnet and the nozzle has a non-magnetic outer surface.

13. The laser welding system of claim 9 , wherein the pressure sensor comprises a strain gauge.

14. 10. The laser welding system of claim 9, wherein the pressure sensor includes a switch that activates when the pressure level applied to the nozzle meets or exceeds the threshold, and activation of the switch generates the corresponding pressure level signal.

15. 10. The laser welding system of claim 9, wherein the handheld laser welding torch includes a laser light guard that blocks reflected laser light.

16. 10. The laser welding system of claim 9, wherein the laser power supply further comprises a user interface operatively connected to the controller, the user interface configured to receive input of an operator code, and the controller configured to verify the operator code and enable activation of the laser light after the operator code is verified.

17. 17. The laser welding system of claim 16, wherein the user interface is configured to display a checklist, and the controller is configured to verify a plurality of acknowledge inputs corresponding to individual elements of the checklist and to enable activation of the laser light after the plurality of acknowledge inputs are verified.

18. 1. A laser welding system comprising: a laser power supply having a controller that controls activation of a laser beam by the laser power supply; a handheld laser welding torch operatively connected to the laser power supply to receive the laser light from the laser power supply; 2. The handheld laser welding torch A nozzle; a pressure sensor that generates a pressure signal based on a pressure level applied to the nozzle; means for determining when the handheld laser welding torch is adjacent to a workpiece to be welded and generating a corresponding proximity signal; the controller receives both the pressure signal and the proximity signal, and the controller is configured to activate the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the handheld laser welding torch is adjacent to the workpiece. Laser welding system.

19. 20. The laser welding system of claim 18, further comprising a wire feeder that supplies consumable wire to the handheld laser welding torch.

20. 20. The laser welding system of claim 18, further comprising a sense lead attachable to the workpiece, the sense lead comprising a work clamp, and the nozzle having an electrically insulating outer surface.

21. 20. The laser welding system of claim 18, further comprising a sense lead attachable to the workpiece, the sense lead comprising a magnet, and the nozzle having a non-magnetic outer surface.

22. 20. The laser welding system of claim 18, wherein the pressure sensor comprises a strain gauge.

23. 20. The laser welding system of claim 18, wherein the pressure sensor includes a switch that activates when the pressure level applied to the nozzle meets or exceeds the threshold, and activation of the switch generates the corresponding pressure level signal.

24. 20. The laser welding system of claim 18, wherein the laser power supply further comprises a user interface operatively connected to the controller, the user interface configured to receive input of an operator code, and the controller configured to verify the operator code and to enable activation of the laser light after the operator code is verified.

25. 25. The laser welding system of claim 24, wherein the user interface is configured to display a checklist, and the controller is configured to verify a plurality of acknowledge inputs corresponding to individual elements of the checklist and to enable activation of the laser light after the plurality of acknowledge inputs are verified.

Images