Laser Welding Beam Shaping for Fast Multi-Material Zone Switching
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Solution Overview
Problem
Laser welding of components made of different materials onto a common base component is slow due to the complexity and time-consuming process of adjusting scanner optics for varying spot sizes, which leads to delays in manufacturing.
Innovation Solution
A method that varies the distribution of laser energy between a core and ring portion of the laser beam to adjust the spot size and intensity profile, allowing for adaptation to different materials without moving the scanner optics, thereby optimizing weld quality and reducing non-productive time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser beam is manually repositioned or re-focused when changing welding zones, then welding precision can be maintained, but productivity decreases due to time-consuming manual intervention
Solution Approach 1:
The system performs self-positioning and self-focusing of the laser beam by using process data from the welding sensor to automatically adjust the laser beam's position and focus depth when transitioning between welding zones, eliminating the need for manual intervention while maintaining welding precision
Solution Approach 2:
The patent replaces manual mechanical repositioning and refocusing operations with an automated control system that uses sensor data and process data to dynamically adjust the laser beam position and focus depth, substituting human operation with automated optical and mechanical control
2Manufacturing precision
If the focus depth is manually adjusted when welding different materials, then welding quality can be maintained, but time is lost during material transitions
Solution Approach 1:
The system determines the focus depth in advance by retrieving material information from process data before welding begins, and pre-positions the laser beam accordingly, so that when transitioning between materials, the focus depth is already optimized and no manual adjustment is needed
Solution Approach 2:
The welding sensor provides real-time process data about the welding zone and material being welded, which feeds back to the control system to automatically adjust the focus depth, creating a closed-loop control system that maintains welding quality without manual intervention
3Adaptability or versatility
If multiple laser beams are used for different welding zones, then welding versatility improves, but device complexity increases
Solution Approach 1:
The patent uses a single laser beam that is dynamically repositioned and re-focused based on the welding zone and material type, allowing the same physical laser source to perform multiple welding functions by changing its position and focus parameters rather than using multiple fixed laser beams
Solution Approach 2:
The single laser beam is designed to perform multiple welding functions across different zones and materials by dynamically adjusting its position and focus depth, making one component serve multiple purposes rather than requiring separate dedicated lasers for each welding type
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 method significantly accelerates the welding process by allowing quick and easy adjustment of spot size and intensity, minimizing defects like spatter and porosity, and ensuring high-quality welds for components made of different materials.
Implementation Method 1
a laser beam is used to weld a workpiece (1)
Implementation Method 2
process data is determined from process data provided by a welding sensor (2)
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
A method for laser welding a workpiece (17), wherein: a laser beam (8) is directed onto the workpiece (17) by means of a scanning optical unit (13); using the laser beam (8) and in any order, a first part (21) is welded to a base element (20) at least in a first welding zone (31) and a second part (22) is welded to the base element (20) in a second welding zone (32); and the first part (21) and the second part (22) are made of different materials, at least in the region of the first and second welding zones (21, 22), the method being characterised in that the laser energy of the laser beam (8) can be split variably at least between a core component (KA) corresponding to a core beam (9) of the laser beam, and a ring component corresponding to a ring beam (10) that surrounds the core beam (9), and in that the splitting of the laser energy into the core component (KA) and the ring component is selected differently when welding the first welding zone (21) and when welding the second welding zone (22). The invention enables faster production of workpieces, wherein parts made of different materials are welded onto one base element.