Annular Nozzle for Laser Processing Head

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Solution Overview

Problem

Laser welding processes face challenges due to the formation of a metal vapor plume, which causes thermal lens effects, weld splashes, and contamination of the laser processing head, leading to impaired seam quality and operational issues.

Innovation Solution

An annular nozzle mounted on the laser processing head, capable of displacement along the laser beam axis, is used to direct auxiliary gas in a controlled manner to suppress the metal vapor plume, with adjustable positioning and orientation of outlet openings to minimize gas consumption and adapt to varying processing conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a cross jet is introduced to protect the laser processing head from metal splashes, then the processing head is protected, but the seam quality deteriorates due to thermal lens effects

Engineering Contradiction:

Improveprotection of laser processing headVSAvoidseam quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The gas flow system is segmented into two distinct functions: an annular nozzle for seam quality control and a cross jet for head protection. This segmentation allows each component to be optimized for its specific purpose without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The annular nozzle acts as an intermediary component between the laser beam and the workpiece, creating a controlled gas atmosphere that prevents thermal lens effects while allowing the cross jet to handle splash protection separately.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If gas nozzles are arranged close to the processing zone to minimize thermal lens effects, then seam quality improves, but the nozzles become contaminated by metal vapor and splashes

Engineering Contradiction:

Improveseam qualityVSAvoidmaintenance of gas nozzles

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The contamination-prone cross jet function is extracted from the annular nozzle system and positioned separately. This allows the annular nozzle to maintain close proximity to the processing zone for optimal seam quality while the cross jet absorbs the contamination from metal splashes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cross jet is designed as a sacrificial component that can be easily replaced when contaminated, protecting the more critical annular nozzle from contamination while maintaining overall system functionality.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If auxiliary gas flow is increased to suppress metal vapor plume, then thermal lens effect is reduced, but gas consumption increases

Engineering Contradiction:

Improveseam qualityVSAvoidauxiliary gas consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The auxiliary gas is delivered locally through the annular nozzle precisely where needed at the processing zone, creating an efficient gas barrier with minimal consumption. The cross jet supplements this locally at the head protection level.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of using excessive gas flow throughout the entire system, partial action is applied with the annular nozzle providing focused gas delivery where it is most effective, reducing overall gas consumption while maintaining seam quality.

Inventive Principle:

Principle #16Partial or excessive action

4Adaptability or versatility

If the annular nozzle is made adjustable and displaceable, then adaptability to varying processing conditions improves, but device complexity increases

Engineering Contradiction:

Improveadjustability of annular nozzleVSAvoidstructure of laser processing head

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The annular nozzle is designed with dynamic capabilities including displacement along the laser beam axis and rotation for angular adjustment. This allows the nozzle to adapt to different processing conditions while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The adjustable annular nozzle serves multiple functions: controlling seam quality, optimizing gas flow patterns, and adapting to different workpiece geometries. This multi-functionality reduces the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution improves seam quality by reducing the thermal lens effect and minimizing the consumption of auxiliary gas, while allowing for flexible handling and reduced contamination of the processing head, enabling more efficient and precise laser processing.

Implementation Method 1

introducing an auxiliary gas into a region surrounding the processing zone of the workpiece

Methodology Applied

Scientific EffectGas flow: Convection

Data Source

PatentUS9969029B2Laser processing head and annular nozzle for a laser processing head

Publication Date: 2018.05.15 TRUMPF LASER GMBH CO KG

AI summary

A laser processing head comprises an optical focusing unit for focusing a laser beam on a processing zone of a workpiece and an annular nozzle arranged coaxially with respect to a central axis of the laser beam for introducing an auxiliary gas into a region surrounding the processing zone. The annular nozzle is mounted on the laser processing head so as to be displaceable along the laser beam axis and can be secured to the laser processing head in different positions along the laser beam axis.