Handheld Laser Welding Guarding With Sensor-Based Beam Alignment
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Solution Overview
Problem
Conventional laser welding tools pose challenges for new users, particularly in achieving quality welds and incorporating laser protection features, making it difficult for even experienced welders to operate effectively.
Innovation Solution
A manually operated laser welding system with a handheld torch that includes a controller for regulating laser power, sensors for distance measurement and user input, and personal protective equipment (PPE) to ensure safe and precise welding operations, featuring a wire-fed system that allows for precise control of the laser beam and filler metal distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser welding tools are used, then welding speed and precision are improved, but ease of operation deteriorates for new users
Solution Approach 1:
The system performs self-alignment by automatically detecting the workpiece position and adjusting the laser beam direction accordingly, eliminating the need for manual alignment by the operator. The controller autonomously processes sensor data and modifies beam parameters to maintain optimal welding conditions throughout the process.
Solution Approach 2:
Manual mechanical alignment operations are replaced by an automated optical-electronic system that uses sensors to detect workpiece position and a controller to adjust laser beam direction, substituting complex mechanical alignment procedures with automated detection and control.
2Object-affected harmful factors
If laser protection features are incorporated, then safety is improved, but device complexity increases
Solution Approach 1:
The system continuously monitors workpiece position and laser beam alignment through sensors, feeding this information back to the controller which automatically adjusts beam direction and parameters. This closed-loop feedback mechanism maintains safety and weld quality without requiring complex manual intervention or multiple independent protection systems.
Solution Approach 2:
The controller serves multiple functions simultaneously: it manages laser beam direction, adjusts beam parameters, processes sensor data for alignment, and coordinates filler metal delivery. This multi-functionality consolidates what would otherwise be separate complex subsystems into a single integrated control unit.
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
The system enables novice users to achieve high-quality welds with improved precision and safety by regulating laser power and ensuring proper alignment and protection, facilitating efficient and effective laser welding processes.
Implementation Method 1
Laser welding is a welding technique used to join multiple pieces of metal through the use of a laser. The laser beam provides a concentrated heat source, enabling a precise control of the heat input and high welding speed
Implementation Method 2
The laser beam provides a concentrated heat source, enabling a precise control of the heat input and high welding speed, creating a weld with low heat input, and a small heat affected zone
Implementation Method 3
a sensor to measure one or more parameters corresponding to a distance (e.g., greater than zero) from a focusing lens to a focal plane (e.g., up or down) at or near a workpiece
Data Source
AI summary
Systems and methods for laser welding are disclosed. A laser welding system includes a manually operated laser welding torch to direct laser power to a workpiece to generate a puddle during a laser welding operation. The welding system includes a controller to regulate activation and regulation of the laser power based on user inputs, sensor inputs, and/or synergic control of a laser power source.