T-Shaped Ceiling Profile Laser Welding for Low Thermal Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing profile members for suspended ceiling systems face challenges in achieving high mechanical strength and rigidity while minimizing weight, and they often suffer from thermal-induced deformation during laser welding.
Innovation Solution
A method involving laser welding with alternating operations at different energy levels to create a laser weld joint in a T-shaped profile member, allowing for adjustable torsional stiffness and reduced thermal load, which minimizes deformation and enhances dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous laser welding is used to join web side walls, then mechanical strength and rigidity are improved, but thermal-induced deformation increases and production speed decreases
Solution Approach 1:
The laser welding process alternates between welding phases (providing strength) and non-welding phases (allowing heat dissipation), creating a periodic action that prevents thermal accumulation. This pulsed welding approach maintains mechanical strength while reducing thermal-induced deformation and enabling higher production speeds.
2Productivity
If laser welding speed is increased to improve productivity, then production speed is improved, but thermal-induced deformation increases
Solution Approach 1:
By implementing periodic welding with alternating welding and non-welding phases, the process allows heat to dissipate during non-welding intervals even at high overall speeds. This enables high productivity while controlling thermal deformation through the rhythmic application and pause of thermal energy.
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 method results in a profile member with improved strength, rigidity, and reduced thermal deformation, enabling higher production speeds and cost-effectiveness by allowing for thinner materials and easier handling, while maintaining high dimensional accuracy.
Implementation Method 1
laser welding the elongate T-shaped profile member for providing a laser weld joint
Data Source
AI summary
A method for manufacturing a profile member for a suspended ceiling system, comprising forming a sheet metal material into an elongate T-shaped profile member with a web having two web side walls and a pair of oppositely disposed flanges projecting from a bottom portion of the web, and laser welding the elongate T-shaped profile member for providing a laser weld joint extending in a longitudinal direction of the T-shaped profile member and joining the two web side walls to each other. The step of laser welding comprises alternatingly performing a first operation and a second operation, the second operation being different from the first operation, whereby a laser weld joint is provided comprising along its extension alternating welded first sections associated to the first operation and second sections associated to the second operation. The present invention also relates to an elongate profile member provided with a laser weld joint.