Fixed Multi-Surface Reflector for 360° Tubular Laser Welding
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Solution Overview
Problem
Current laser-welding techniques for tubular components in high-production settings face challenges in achieving consistent and high-quality 360° circumferential welds due to complex and error-prone setup requirements, particularly with multiple adjustable optical reflectors that demand precise angular and lateral adjustments, leading to prolonged setup times and potential overheating or underheating issues.
Innovation Solution
A single, fixed optical reflector with multiple optically reflecting surfaces angled at an obtuse angle is used, requiring only vertical adjustment of the workpiece relative to the reflector, eliminating the need for lateral and angular adjustments, allowing for a 'set it and forget it' configuration with minimal setup time and effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple adjustable optical reflectors are used to achieve 360° circumferential weld, then weld coverage is improved, but setup complexity and time increase
Solution Approach 1:
The patent combines multiple optical reflector functions into a single integrated reflector assembly with multiple fixed reflecting surfaces. Instead of using separate adjustable reflectors, the invention merges them into one unitary structure that provides all necessary reflection angles simultaneously, eliminating the need for multiple independent adjustment mechanisms while maintaining complete circumferential weld coverage.
Solution Approach 2:
The optical reflector is pre-configured with fixed reflecting surfaces at specific angles during manufacturing. This preliminary action of setting the correct angles and positions during fabrication eliminates the need for complex runtime adjustments during setup, allowing the system to achieve precise 360° weld coverage immediately upon installation with minimal adjustment to laser source position.
2Productivity
If multiple adjustable optical reflectors are used to cover all sides of workpiece, then weld coverage is improved, but adjustment time and error probability increase
Solution Approach 1:
The patent combines multiple optical reflector functions into a single integrated reflector assembly with multiple fixed reflecting surfaces. Instead of using separate adjustable reflectors, the invention merges them into one unitary structure that provides all necessary reflection angles simultaneously, eliminating the need for multiple independent adjustment mechanisms while maintaining complete circumferential weld coverage.
Solution Approach 2:
The invention accepts a simple, fixed optical reflector design that may have limited adjustability but provides sufficient performance for high-volume production. The focus shifts from creating a highly adjustable, complex system to using a simpler, more robust system that requires minimal setup and maintenance, trading some flexibility for reliability and speed in manufacturing environments.
3Manufacturing precision
If complex optical reflector systems are used to redirect laser beam, then weld coverage is improved, but cost and maintenance difficulty increase
Solution Approach 1:
The patent combines multiple optical reflector functions into a single integrated reflector assembly with multiple fixed reflecting surfaces. Instead of using separate adjustable reflectors, the invention merges them into one unitary structure that provides all necessary reflection angles simultaneously, eliminating the need for multiple independent adjustment mechanisms while maintaining complete circumferential weld coverage.
Solution Approach 2:
The fixed optical reflector system is designed to be inherently stable and self-maintaining. By eliminating adjustable mechanisms, the system removes the need for complex calibration and alignment procedures during maintenance. The reflector assembly maintains its optical configuration automatically without requiring operator intervention for adjustment, significantly easing maintenance requirements.
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 results in consistently high-quality, repeatable 360° circumferential welds with reduced variability and significantly faster setup times, enhancing weld quality and production throughput by simplifying the setup process and eliminating the need for iterative adjustments.
Implementation Method 1
a single, fixed optical reflector having a first optically reflecting side surface and a second optically reflecting side surface
Data Source
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AI summary
Device and method for laser welding around a circumference of a workpiece. A fixed, non-movable unitary optical reflector is provided, which has a pair of optical reflecting surface portions on a first side surface and a second side surface, respectively, arranged at an obtuse angle relative to each other. A workpiece is positioned and fixed in an assembly that includes the unitary optical reflector. During setup, the vertical distance is adjusted between the unitary optical reflector and the workpiece along an axis that is transverse to a longitudinal axis of the workpiece without any adjustment of the reflecting surfaces, which remain fixed during setup. The first and second side surfaces define a curve that is transverse to the longitudinal axis. Once setup has been completed, a laser beam is directed so that it moves along the optical reflector to thereby produce a 360 degree circumferential weld around the workpiece.