Concealed Seam Joining with Exploratory Seam Detection
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Solution Overview
Problem
Current methods for joining concealed workpiece parts using an energy beam are inefficient due to the need for complex and costly gauging and alignment processes, leading to prolonged cycle times and increased costs, as the joining seam cannot be monitored in-line and is prone to defects from production tolerances.
Innovation Solution
A method where an exploratory seam is produced on the upper workpiece part to detect the concealed joining contour's position and alignment using a detector, allowing the energy beam's trajectory to be corrected before the actual joining process, enabling precise placement of the joining seam without extensive initial gauging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex gauging and alignment processes are used to ensure precise joining seam placement, then manufacturing precision is improved, but productivity deteriorates due to prolonged cycle times
Solution Approach 1:
The patent performs preliminary gauging of workpiece dimensions and positions before the joining process. The controller stores this gauging data and uses it to calculate and adjust the energy beam trajectory in advance, allowing the actual joining to proceed without time-consuming real-time measurements, thus resolving the contradiction between precision and productivity
Solution Approach 2:
The patent implements a feedback mechanism where gauging data from workpiece measurements is fed back to the controller, which then adjusts the energy beam trajectory accordingly. This closed-loop control system ensures precise joining seam placement while maintaining efficient production cycle times by eliminating the need for repeated adjustments during the joining process
2Measurement precision
If traditional gauging methods are used to detect the joining contour position, then measurement accuracy is improved, but device complexity increases due to complicated and costly gauging equipment
Solution Approach 1:
The patent replaces complex mechanical gauging and alignment systems with an optical measurement system. The optical measurement device non-contactly measures workpiece dimensions and positions, and the controller processes this data to determine the energy beam trajectory, thereby achieving high measurement precision while significantly reducing device complexity and cost
Solution Approach 2:
The patent creates a digital model or representation of the workpiece geometry through optical measurement. The controller uses this copied geometric information to calculate the joining trajectory without requiring physical contact or complex mechanical measurement apparatus, simplifying the overall system while maintaining measurement accuracy
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 reduces cycle times and costs by allowing in-line quality monitoring and precise alignment of the energy beam, ensuring a secure and permanent connection between workpiece parts while minimizing material and energy consumption.
Implementation Method 1
joining two workpiece parts (3, 2) to one another by means of an energy beam (10)
Implementation Method 2
The energy beam (10) is directed onto an upper side (2a) of the upper workpiece part (2)
Implementation Method 3
By means of a detector (11), a boundary (7, 8) is detected at which a surface area (A1) of the upper workpiece part (2) which does not have any contact with the lower workpiece part (3) borders a surface area (A2) of the upper workpiece part (2) which does have contact with the joining contour (4)
Data Source
AI summary
A method for joining concealed workpiece parts by an energy beam, wherein a lower workpiece part and an upper workpiece part are positioned relative to each other; the upper workpiece part contacts the lower workpiece part along a joining contour; the energy beam is directed onto an upper side of the upper workpiece part, moved along the joining contour by a controller, in order to join the upper workpiece part to the joining contour; an exploratory seam is produced on the upper work piece part, for detecting the joining contour; a detector detects a boundary at which a surface area of the upper work piece part borders a surface area of the upper work piece part which does have contact with the joining contour; the controller registers a position of the boundary and compares it with a target position of the boundary which is stored in the controller.