Alternating Protective Lenses for Cleaner Laser Welding
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Solution Overview
Problem
Automated laser welding systems in battery assembly face defects due to contamination of protective lenses by spatters and fumes, leading to decreased welding quality and increased production costs, as monitoring and maintenance are labor-intensive and difficult to predict.
Innovation Solution
A laser protection system with a drive mechanism for alternating protective lenses and a cleaning member, allowing for automatic cleaning and maintenance during the welding process, ensuring continuous operation and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective lenses are used in automated laser welding systems, then welding quality is maintained, but the lenses become contaminated by spatters and fumes leading to decreased welding quality over time
Solution Approach 1:
The protective lens system is segmented into multiple lenses (first protective lens and second protective lens) that can be alternately positioned in front of the laser source. This segmentation allows one lens to be used while another is cleaned or replaced, preventing contamination from compromising welding quality.
Solution Approach 2:
The system dynamically switches between multiple protective lenses using a drive mechanism that moves lenses between operating positions and non-operating positions. This dynamic arrangement ensures continuous protection while allowing maintenance of individual lenses.
2Reliability
If manual monitoring and maintenance of protective lenses is performed, then contamination can be detected, but the process is labor-intensive and difficult to predict
Solution Approach 1:
The system provides self-service through automated lens cleaning members that actively remove contaminants from protective lenses during the welding process, eliminating the need for manual monitoring and maintenance while ensuring consistent lens quality.
Solution Approach 2:
The cleaning members continuously or periodically clean the protective lenses during welding operations, maintaining lens quality without interrupting the welding process or requiring manual intervention.
3Reliability
If multiple protective lenses are used with alternating positions, then lens contamination is prevented, but device complexity increases
Solution Approach 1:
The drive mechanism serves multiple functions: it positions protective lenses in front of the laser source, moves cleaning members to clean the lenses, and switches between operating and non-operating positions. This multi-functionality reduces overall system complexity despite the presence of multiple lenses.
4Productivity
If protective lenses are cleaned during operation, then production costs are reduced, but the cleaning process must be integrated into the welding system
Solution Approach 1:
The cleaning members are merged with the protective lens system, allowing cleaning to be performed in close proximity to the lenses without requiring separate external equipment. This integration reduces production costs by preventing quality defects while minimizing additional system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system maintains consistent welding quality by automatically handling foreign substances, reducing defects and production costs associated with manual monitoring and maintenance.
Implementation Method 1
a laser source configured to sequentially emit a plurality of laser beams to a plurality of work targets that are discretely supplied
Data Source
AI summary
The present disclosure provides a laser protection system including a laser source configured to sequentially radiate a laser beam to two or more work targets that are discretely supplied, a plurality of protective lenses disposed between the laser source and the work targets, the plurality of protective lenses each allowing the laser beam to pass therethrough at different times, and a drive mechanism having the plurality of protective lenses movably mounted thereon.