Handheld Laser Welding Interface With Sensor-Based Safety Control
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Solution Overview
Problem
Conventional laser welding systems pose challenges for new users, particularly in achieving quality welds and incorporating safety features, as they require precise control and unfamiliarity with laser-specific operations.
Innovation Solution
A manually operated laser welding system with a controller that regulates laser power based on user and sensor inputs, featuring a handheld torch with a user interface to select and adjust laser profiles, and a safety helmet with sensors for enhanced control and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser welding systems are used, then precise control and high welding speed are achieved, but the system becomes difficult to operate for new users and requires familiarity with laser-specific operations
Solution Approach 1:
The system incorporates automated functions that allow the welding system to self-regulate and self-adjust parameters based on pre-programmed settings, reducing the burden on operators to manually control complex laser parameters while maintaining weld quality
Solution Approach 2:
The system provides pre-configured parameter sets that automatically adjust laser power, pulse duration, and other critical parameters based on the selected welding mode, allowing operators to achieve consistent results without deep understanding of laser physics
2Object-affected harmful factors
If laser protection features are incorporated, then user safety is improved, but the system complexity increases
Solution Approach 1:
The patent integrates multiple safety functions including sensors, interlocks, and protective features into a unified safety management system that operates automatically, reducing the apparent complexity for users while maintaining comprehensive protection
Solution Approach 2:
The system incorporates sensors and monitoring mechanisms that continuously feedback on safety conditions and automatically adjust or shut down operations when safety thresholds are exceeded, providing passive safety without requiring complex user intervention
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 precise control over laser power and scanning patterns, improving weld quality and safety by allowing operators to easily select and adjust settings through a user-friendly interface, while the safety features protect users from intense light exposure.
Implementation Method 1
a laser source to generate a laser to perform a welding operation
Implementation Method 2
The laser beam provides a concentrated heat source, enabling a precise control of the heat input
Implementation Method 3
a handheld laser welding torch to direct the laser power to a workpiece via a nozzle, wherein the nozzle is configured to output a laser beam
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
Systems and methods for laser welding are disclosed. A laser welding system includes a hand held laser welding tool to direct laser power to a workpiece to generate a weld 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. A laser welding system is disclosed, comprising: a handheld laser welding torch (50) to direct the laser power to a workpiece via a nozzle, wherein the nozzle is configured to output a laser beam; a user interface configured to receive an input, allowing an operator to search, select or build one or more laser welding parameters, laser welding profiles, workpiece characteristics, or filler material characteristics; and a laser beam controller to control application of the laser beam from the handheld laser welding torch to the workpiece based on the input.