Disc-Shaped Sample Chamber Laser Welding
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Solution Overview
Problem
The existing disc-shaped sample chambers used in steel making processes face issues with burr formation due to inadequate fixation, increased production costs, and additional manual steps required for clip-based coupling, which complicates assembly and analysis.
Innovation Solution
A disc-shaped sample chamber where the chamber bodies are bonded using a laser-based spot welding scheme on at least one lateral face, reducing assembly and separation complexity and costs, and allowing for easier production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If clip-based fixation is used to assemble chamber bodies, then the sample chamber can be assembled and held together, but burrs form on the sample and additional manual steps are required for assembly and separation
Solution Approach 1:
The patent replaces the mechanical clip-based fixation system with a laser-based welding system. The laser welding process directly bonds the chamber bodies together through melting and fusion, eliminating the need for mechanical clips and their associated assembly/disassembly operations. This substitution resolves the contradiction by providing strong fixation without the complexity of mechanical attachment mechanisms.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (clip-based) to thermal (laser-based). By changing the fundamental parameter of how the chambers are joined - from mechanical interlocking to thermal fusion - the invention eliminates burr formation and simplifies the assembly process while maintaining strong fixation strength.
2Reliability
If clip-based coupling is used to assemble chamber bodies, then the chambers can be connected, but production time and costs increase due to additional manual steps
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated laser welding. The laser system can automatically position and weld the chamber bodies together, eliminating the need for manual clip installation and removal. This automation significantly improves production efficiency while maintaining reliable connections through consistent welding parameters.
Solution Approach 2:
The laser welding process performs the bonding action in a single continuous operation rather than requiring multiple manual steps for clip installation, positioning, and securing. The preliminary positioning of chambers is followed by immediate welding, eliminating intermediate manual operations and reducing overall production time.
3Stress or pressure
If preloaded spring clips are used to withstand expanding gas pressure, then the sample chamber can contain the molten metal sample, but the clips require strong fixation and perfect connection to prevent burr formation
Solution Approach 1:
The patent replaces the mechanical clip system with laser welding to contain the gas pressure. The welded joint creates a permanent, seamless bond between chamber bodies that can withstand the expanding gas pressure without requiring the high precision connections needed for mechanical clips. The thermal fusion eliminates gaps and weak points where burrs could form.
Solution Approach 2:
The laser welding process creates a composite structure where the chamber bodies are fused together with a weld seam that integrates the two materials. This composite bonding method provides superior pressure resistance compared to mechanical clips, as the welded joint becomes a continuous structure without the stress concentration points inherent in mechanical fastening systems.
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 approach significantly reduces assembly time and costs, facilitates easy separation of chamber bodies, and improves production yield through precise bonding line measurement and inspection.
Implementation Method 1
the left body and the right body which are coupled to each other to define the disc-shaped sample space, and a welded bonding portion formed on at least one lateral face of the chamber body to bond the left body and the right body to each other
Data Source
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AI summary
Disclosed is a disc-shaped sample chamber for collecting molten metal, the chamber comprising: a chamber body having a left body and a right body bonded to each other to define a disc-shaped sample space therebetween; an inlet extending upward from the chamber body and connecting the sample space with the outside; and a welded bonding portion disposed on at least one lateral face of the chamber body for bonding the left body and the right body to each other. Further, a probe having the chamber is disclosed.