Dual-Weave Welding System for Large Joint Variation
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Solution Overview
Problem
Conventional welding techniques struggle to create sufficient weld joints for work pieces with large joint variations, as they often require stricter manufacturing tolerances or specialized laser-based hybrid systems that do not fully address the issue of achieving wide enough welds.
Innovation Solution
A dual-weave welding system that employs two welding devices, one moving along a first weaving path and the other along a second weaving path, controlled by a processor to create a weld joint in a gap between work pieces, allowing for simultaneous lateral and oscillatory movement to generate a strong weld joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding techniques are used, then the welding process is simple, but the weld joint is insufficient for large joint variations
Solution Approach 1:
The patent implements dynamic weaving motion for both the laser beam and arc electrode, where each welding component oscillates independently along predetermined paths. This dynamic motion allows the welding system to adapt to varying gap widths by distributing heat input across a wider area, creating effective weld joints even when joint variation exceeds traditional welding capabilities.
Solution Approach 2:
The patent combines laser welding and arc welding into a hybrid system where both processes operate simultaneously with coordinated weaving motions. The laser beam creates deep penetration while the arc fills the gap, and their combined effect with independent oscillation patterns enables the system to handle large joint variations that neither process could achieve alone.
2Manufacturing precision
If stricter manufacturing tolerances are applied, then the joint variation decreases, but the manufacturing time and costs increase
Solution Approach 1:
Instead of changing the physical dimensions of workpieces to reduce joint variation, the patent changes the welding process parameters by implementing dual weaving motions with adjustable amplitudes, frequencies, and phases. This allows the system to compensate for large joint variations through process adaptation rather than requiring stricter manufacturing tolerances, thereby maintaining productivity.
3Length of moving object
If laser beam oscillation is used, then the weld joint depth increases, but the weld joint width is still insufficient
Solution Approach 1:
The patent adds another dimension of motion by implementing weaving (lateral oscillation) in addition to the primary linear motion. Both the laser and arc perform weaving motions that extend the weld zone laterally, transforming the weld geometry from a narrow deep profile to a wider profile that can span large gap variations while maintaining penetration depth.
Solution Approach 2:
The system employs dynamic weaving motion for both laser and arc with independent control of oscillation parameters. By coordinating the timing, amplitude, and phase of each component's weaving motion, the system dynamically adjusts the heat distribution pattern to achieve both sufficient depth and width in the weld joint, overcoming the limitation of static or single-component oscillation.
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
Enables the creation of sufficiently strong weld joints in gaps with large variations, overcoming the limitations of traditional welding systems by effectively combining laser and arc welding techniques to achieve wider welds without increasing manufacturing costs.
Implementation Method 1
the laser beam oscillates, it generates a keyhole in the work piece that is surrounded by molten metal
Implementation Method 2
a consumable material fed from the arc welder
Data Source
AI summary
A dual-weave welding system is disclosed. The system may have a first welding device configured to create a weld joint in a gap between two or more work pieces by moving a first welding component along a first weaving path. The system may also have a second welding device configured to create the weld joint in the gap by moving a second welding component along a second weaving path. The system may further have a controller that sends commands to control the movement of the first welding device and the second welding device.