Dynamic Laser Spot Control for Variable-Density Soldering
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Solution Overview
Problem
Existing laser soldering methods are limited by fixed laser power settings and unadjustable light spot sizes, leading to inconsistent heating energy density and reduced soldering quality.
Innovation Solution
A laser soldering method using a dynamic light spot, where the distance between lenses is adjusted to change the light spot size and heating energy density in real-time during the soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the focal length of the lens is fixed, then the structure is simple, but the light spot size is unadjustable leading to unadjustable heating energy density
Solution Approach 1:
The patent applies the dynamics principle by making the lens system adjustable during operation. Specifically, the focal length of the lens is made variable through an adjustable lens structure, allowing the light spot size and heating energy density to be dynamically adjusted according to different soldering requirements, while maintaining a relatively simple overall structure.
2Adaptability or versatility
If the laser power is configured offline, then the system is stable, but the power cannot be adjusted online leading to inconsistent soldering quality
Solution Approach 1:
The patent applies the parameter changes principle by enabling adjustment of key parameters (laser power and focal length) during the soldering process. The control module allows online modification of laser power output, and the adjustable lens structure enables real-time changes in focal length, allowing the system to adapt to different soldering conditions without requiring complete reconfiguration.
3Manufacturing precision
If same heating energy density is provided, then the laser power remains constant, but soldering quality deteriorates for different soldering events
Solution Approach 1:
The patent applies the feedback principle through its control module that monitors soldering conditions and adjusts laser parameters accordingly. The system provides feedback control by detecting the actual soldering state and modifying laser power and focal length to maintain optimal soldering quality across different events, preventing defects while managing system complexity through intelligent control.
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 allows for multiple heating densities to be achieved, improving soldering quality by ensuring optimal energy delivery for varying soldering conditions using the same laser power.
Implementation Method 1
a laser module (11) used to radiate a laser beam (60) toward the laser lens (13) to form a light spot (61) on a soldering target (2)
Implementation Method 2
the power of the laser module must be configured before a soldering stage... the focal length of the lens is fixed, and thus the size of the light spot formed on a soldering target is also fixed
Data Source
AI summary
A laser soldering method using dynamic light spot is provided and includes following steps: executing a soldering to control a laser module to radiate toward multi-lens to form a light spot on a soldering target; and, adjusting a lens distance between the multi-lens based on a spot-adjustment condition to adjust a light spot size of the light spot when the spot-adjustment condition is met in the soldering. The disclosure may provide multiple heating densities respectively adequate to different soldering status via adjusting the light spot size when using same laser power, so as to improve the soldering quality.