Laser Brazing Wire Alignment Using a Beam-Blocking Jig

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Solution Overview

Problem

Current laser brazing systems require manual inspection of the braze wire position, which disrupts productivity and can result in defective parts due to the need for additional auxiliary lasers to monitor the wire's alignment, as using the original laser for monitoring causes the wire to melt.

Innovation Solution

A laser brazing system that employs a jig to block and measure the laser beam, allowing for automatic determination of the braze wire's position using a control unit that compares detected light signals without the need for additional lasers, by positioning the jig in different alignments to assess the wire's alignment relative to the laser beam.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the original laser is used for monitoring the position of the wire, then the monitoring function is achieved, but the wire will melt

Engineering Contradiction:

Improvewire position monitoringVSAvoidwire melting

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

A jig is introduced as an intermediary component that blocks the laser beam and reflects it to the detector. The jig serves as a mediator between the laser source and the wire position monitoring system, allowing the laser to be used for monitoring without directly irradiating the wire. The jig's blocking surface reflects the laser beam when positioned at specific locations relative to the wire, enabling indirect monitoring.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system creates an optical copy or reflection of the laser beam path by using the jig's blocking surface to reflect the beam to the detector. Instead of directly measuring the wire position with the laser, the system measures the reflected beam position, which copies the wire position information indirectly through the jig's geometric relationship with the wire.

Inventive Principle:

Principle #26Copying

2Reliability

If manual inspection of the wire position is performed, then the wire position can be verified, but productivity decreases due to process stoppage

Engineering Contradiction:

Improvewire position verificationVSAvoidmanufacturing output

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables automatic self-monitoring of the wire position through the jig and detector configuration. The laser beam, jig, and detector work together in an automated feedback system that continuously monitors wire position without requiring external manual inspection, allowing the process to run continuously while maintaining quality control.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The detector provides continuous feedback about the wire position by measuring the reflected laser beam position. This feedback loop allows real-time monitoring and automatic detection of wire position deviations, enabling immediate corrective action without stopping the production process.

Inventive Principle:

Principle #23Feedback

3Reliability

If manual inspection is performed after a certain number of brazing operations, then wire position can be checked, but defective parts may already be produced

Engineering Contradiction:

Improvewire position detectionVSAvoidtime to detect wire misalignment

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The monitoring system operates continuously throughout the brazing process rather than periodically. The laser beam continuously illuminates the jig, and the detector continuously measures the reflected beam position, providing uninterrupted monitoring of wire position. This continuous action ensures immediate detection of any wire position drift, preventing defective parts from being produced.

Inventive Principle:

Principle #20Continuity of useful action

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

Enables reliable and automatic monitoring of the braze wire's position, reducing measurement faults and the need for manual intervention, thus improving productivity and preventing defective parts by ensuring accurate alignment without additional lasers.

Implementation Method 1

blocking at least a first part of the emitted laser beam by means of a jig

Methodology Applied

Scientific EffectLight blocking/absorption: Absorption (EM radiation)

Implementation Method 2

measuring the amount of emitted light of the laser beam passing the jig

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Data Source

PatentEP3612337B1A laser brazing system with a jig for contacting the brazing wire and for blocking a first part of a laser beam in association with a detector ;method of monitoring a laser brazing system

Publication Date: 2021.03.17 VOLVO TRUCK CORP

Figure 1
Figure 2a~2c
Figure 3a~3b

AI summary

The invention relates to a laser brazing system (100), comprising a braze tool (110) having a laser (112) configured to emit a laser beam (114) along a radiation path (RP), and a braze wire tool (120) being configured to guide a braze wire (122) along a wire path (WP) intersecting the laser beam (114). The system (100) comprises a jig (130) comprising a first alignment surface (132a) and a first blocking surface (134a), wherein the first alignment surface (132a) is configured to be in contact with the braze wire (122) while the first blocking surface (134a) blocks at least a first part of the emitted laser beam (114), and a detector (140) arranged in the radiation path (RP) and configured to detect the emitted light of the laser beam passing the jig (130). A method of monitoring a laser brazing system is also provided.