Brazing Head Force Compensation for Orientation-Dependent Control
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Solution Overview
Problem
Existing brazing processes, such as laser brazing, face challenges in accurately controlling the lateral force applied to components due to unaccounted forces from the brazing head's orientation and wire delivery cable tension, leading to inconsistent joint formation and potential failures.
Innovation Solution
A system with a brazing head featuring a support body, an articulated arm, and sensors to measure and correct the lateral force, accounting for gravitational orientation and arm position relative to the support body, ensuring consistent force application by adjusting the arm's position to maintain a predetermined target force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a lateral force sensor is used to measure the lateral force applied to the component, then the force measurement capability is improved, but the measurement precision deteriorates because the sensor does not account for additional forces from brazing head orientation and wire delivery cable tension
Solution Approach 1:
The system continuously monitors the actual lateral force applied to the component through the force sensor, compares it with the target force value, and automatically adjusts the brazing head position to maintain the desired force level. This closed-loop feedback control compensates for variations in gravitational forces and cable tension, ensuring reliable and accurate force measurement throughout the brazing process.
Solution Approach 2:
The patent replaces simple mechanical force sensing with an integrated system that combines force sensing, orientation sensing (inertial measurement), and automated positional control. This substitution transforms the mechanical measurement system into an intelligent control system that accounts for multiple physical factors simultaneously, improving both measurement accuracy and reliability.
2Adaptability or versatility
If the brazing head is positioned in different orientations to accommodate complex geometries, then the adaptability is improved, but the force control precision deteriorates due to unaccounted gravitational forces and cable tension variations
Solution Approach 1:
Before the brazing process begins, the system performs a calibration routine where it moves the brazing head through various orientations and positions while recording the forces measured by the force sensor. These calibration data are stored and used during actual brazing operations to compensate for orientation-dependent gravitational forces and cable tension variations, ensuring precise force control across all positions.
Solution Approach 2:
The system dynamically adjusts control parameters based on the brazing head's orientation and position. By continuously monitoring orientation sensors and using calibration data, the system modifies the target force values and control settings to account for changing gravitational components and cable tensions, maintaining manufacturing precision regardless of head orientation.
3Stability of the object's composition
If the arm position is adjusted to maintain constant lateral force, then the force consistency is improved, but the device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The brazing head integrates multiple functions into a single unified system: force sensing, orientation sensing, positional control, and automated adjustment. Rather than adding separate independent systems, the patent creates a multi-functional integrated unit where sensors and actuators work together seamlessly, improving force consistency while minimizing the increase in overall 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
This solution enables precise control of the lateral force applied during the brazing process, improving the accuracy and consistency of joint formation by compensating for additional forces, thereby enhancing the quality and reliability of the brazing operation.
Implementation Method 1
sensing additional forces acting on the brazing head to provide a determined set of additional forces
Implementation Method 2
measuring a lateral force value with a force sensor disposed on the arm
Implementation Method 3
laser brazing where a filler material is melted with a laser and flows into or forms a joint between the different components
Data Source
AI summary
Disclosed techniques compensate for variable forces applied to a brazing head in order to more accurately maintain application of a desired lateral force by a brazing wire, filling wire or tracking finger extending from the brazing head to a component. Orientation of the brazing head is determined relative to gravity and the angle of a movable arm of the brazing head relative to a support body of the brazing head. A lateral force value measured by a lateral force sensor is adjustable based on the determined orientation of the brazing head and the determined angle of the arm relative to the support body in order to provide a corrected or adjusted lateral force value. At least a portion of the brazing head is repositioned relative to the component if the corrected lateral force value deviates from a predetermined value.