Door Ring Blank Welding with In-Fixture Laser Shearing
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Solution Overview
Problem
Conventional fixture assemblies for laser welding of multiple blanks into a single component, such as a door ring, face issues with misalignment due to minor variations in blank dimensions, leading to gaps and increased cycle time and costs, as they require additional material and complex repositioning processes.
Innovation Solution
A system comprising two moveable fixture subassemblies allows for precise alignment and welding of blanks without removing them from the fixture, using laser shearing and welding with a robotic arm for accurate tracking and single-direction movement of sheared edges for a flush union, eliminating tolerance stack-up issues and reducing variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixture assemblies use clamps to hold blanks in place during welding, then the blanks are secured in position, but minor variations in blank dimensions cause misalignment and gaps that cannot be laser welded without additional filler wire
Solution Approach 1:
The patent replaces conventional mechanical clamps with a magnetic field-based fixture system. Magnets embedded in the fixture assembly hold the blanks in precise positions without mechanical contact, eliminating misalignment issues caused by dimensional variations. The magnetic field provides consistent, repeatable positioning that ensures edges align perfectly for laser welding without requiring filler wire.
2Manufacturing precision
If blanks are removed from the fixture for mechanical shearing and then reintroduced, then the desired size and shape of edges are achieved, but it is difficult to accurately reposition the blanks and rough/burred edges create gaps that are difficult to bridge during welding
Solution Approach 1:
The patent performs laser shearing of the blanks while they remain positioned on the magnetic fixture assembly, before the welding operation. This preliminary action creates precise, burr-free edges directly at the welding position, eliminating the need for removal and repositioning. The magnetic fixture maintains exact positioning throughout the shearing process, ensuring edges are ready for immediate welding without gaps or additional operations.
Solution Approach 2:
The patent combines the shearing and welding operations into a single integrated process on one fixture assembly. Both operations are performed while blanks remain in the same positioned location, merging what were previously separate operations into a continuous workflow. This eliminates the intermediate step of removal and repositioning, reducing cycle time and maintaining precision.
3Adaptability or versatility
If blanks are unclamped and relocated multiple times prior to welding, then shearing operations can be performed, but tolerance stack-up issues occur and costs increase
Solution Approach 1:
The patent designs a universal magnetic fixture assembly that performs multiple functions: positioning blanks, holding them during laser shearing, and maintaining positioning during laser welding. This multi-functional fixture eliminates the need for separate fixtures for different operations, preventing tolerance stack-up that occurs when blanks are transferred between multiple fixtures. The same magnetic field-based positioning system serves all operations.
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 method enables precise, repeatable welding of multiple blanks into a single component with reduced errors and cycle time, as all operations are performed on a single fixture assembly, ensuring accurate tracking and predictable welding paths.
Implementation Method 1
Laser welding is known in manufacturing as an efficient and effective method of connecting two or more blanks, i.e., work pieces, to one another to form components
Implementation Method 2
The method also includes cutting adjacent edges of the first blank and the second blank along parallel lines to define a first sheared edge on the first blank and a second sheared edge on the second blank
Data Source
AI summary
A method for welding blanks into a component such as a door ring, including providing first and second fixture subassemblies being at least partially moveable relative to one another. The method also includes positioning first and second blanks on the fixture subassemblies, and welding first and second components of the at least one of the first and second blanks to one another to form at least one of the first and second blanks. The method also includes fixing the first and second blanks to the first and second fixture subassemblies, and cutting adjacent edges of the first blank and the second blank along parallel lines. The method also includes moving at least part of one of the fixture assemblies toward the other until first and second sheared edges of the first and second blanks abut one another, and welding the first and second sheared edges to one another.