Laser Brazing Head Control for Real-Time Wire-to-Beam Alignment
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Solution Overview
Problem
Manual calibration of laser brazing/welding heads is time-consuming and does not account for reaction forces applied to the filler wire, leading to inefficiencies in the welding/brazing process.
Innovation Solution
Implementing a system with precision computer vision and closed-loop feedback control using a servomotor to adjust the positioning of the filler wire, applying corrective side forces to maintain alignment between the laser beam and filler wire, thereby compensating for reaction forces and improving the integrity of the weld/braze seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual calibration is used to position the laser beam and wire feeder, then the equipment can be set up, but the process is time-consuming and does not account for reaction forces
Solution Approach 1:
The patent implements a feedback control system using vision sensors to detect wire position and a servomotor to adjust wire feeder positioning in real-time. The system continuously monitors the distance between the wire and laser beam, compares it to a target value, and automatically corrects positioning errors by applying counteracting forces through the servomotor, eliminating manual calibration time
Solution Approach 2:
The system performs self-calibration by automatically detecting its own positioning errors through vision sensors and correcting them using the servomotor-driven wire feeder. The closed-loop control enables the equipment to self-adjust without operator intervention, making the calibration process autonomous and eliminating the need for time-consuming manual procedures
2Reliability
If manual calibration is used, then setup can be completed, but reaction forces from part variations and environmental changes are not accounted for
Solution Approach 1:
The vision sensor continuously monitors wire position and provides real-time feedback to the control system. When part variations or environmental changes cause positioning drift, the system detects the deviation and automatically compensates by adjusting the wire feeder position through the servomotor, maintaining accurate wire-to-beam alignment throughout the welding process
Solution Approach 2:
The system transitions from static manual calibration to dynamic automated adjustment. The servomotor enables real-time motion compensation as the welding process progresses, allowing the wire feeder to adapt to changing conditions such as part variations, thermal expansion, and reaction forces, thereby maintaining positioning accuracy throughout the entire operation
3Manufacturing precision
If automated wire-to-beam alignment with closed-loop control is implemented, then real-time positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical calibration mechanisms with an automated control system combining vision sensors and a servomotor. Instead of requiring manual mechanical adjustment of the wire feeder and laser head positions, the system uses optical detection and electronic control to achieve precise alignment, reducing mechanical complexity while improving precision
Solution Approach 2:
The servomotor serves multiple functions: it positions the wire feeder during calibration, maintains wire-to-beam alignment during welding, and compensates for positioning drift throughout the process. The vision sensor also performs multiple tasks including wire detection, position measurement, and alignment verification. This multi-functionality reduces the need for separate dedicated components, managing overall system complexity
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 minimizes manual calibration and correction time, reduces manufacturing costs, and enhances the strength and integrity of the weld/braze seam by ensuring real-time automated wire-to-beam alignment during the welding/brazing process.
Implementation Method 1
a beam emitter operable to melt the discharged filler wire
Implementation Method 2
by causing coalescence—the process by which two separate units or adjacent sections of a single unit grow together, fuse, or merge into a single body/section
Implementation Method 3
a system with precision computer vision and closed-loop feedback control using a servomotor to adjust the positioning of the filler wire, applying corrective side forces to maintain alignment
Implementation Method 4
the filler material is heated to a working temperature that is slightly above its melting point, yet well below the melting temperature of the parts being joined, then allowed to flow into the joint region and cool to form the final bond
Data Source
AI summary
Presented are intelligent non-autogenous metalworking systems and control logic for automated wire-to-beam alignment, methods for making/using such systems, and robot-borne laser welding/brazing heads with closed-loop control for real-time wire alignment. A method for controlling operation of a non-autogenous workpiece processing system includes a system controller receiving sensor signals from a position sensor indicative of a location of filler wire discharged into a joint region by a wire feeder. Using the received sensor signals, the controller determines a displacement between the wire location and a location of a beam emitted onto the joint region by a beam emitter. If the wire displacement is greater than a threshold wire displacement value, the controller responsively determines a corrective force calculated to reduce wire displacement to below the threshold wire displacement value. The controller then commands the actuator to pivot the processing head to thereby apply the corrective force to the discharging filler wire.