Laser Bundle Intensity Sensing for Consistent Weld Delivery
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Solution Overview
Problem
In simultaneous through transmissive infrared (STTIr) laser welding, maintaining the integrity of laser delivery bundles is critical for repeatable and accurate welds, but existing methods lack effective monitoring and adjustment mechanisms to ensure consistent laser light intensity at the weld area.
Innovation Solution
A method involving a smart part with laser light intensity sensors in the weld area, coupled with a controller that adjusts laser channel intensities based on sensed light levels, using fiber optic bundles and waveguides to homogenize and monitor laser light, and compares sensed intensity to expected levels to determine bundle integrity and adjust accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser delivery bundles are used to deliver laser light to the weld area, then the welding process can be performed, but the integrity of the laser delivery bundles cannot be monitored, leading to inconsistent laser light intensity
Solution Approach 1:
The patent implements feedback by placing sensors in the weld area that detect the actual laser light intensity delivered through each fiber optic bundle. These sensors provide real-time feedback signals to a controller, which compares the detected intensity against expected values and adjusts laser channel outputs accordingly to maintain consistent welding parameters despite bundle degradation
Solution Approach 2:
The patent uses an intermediary smart part or test coupon placed in the weld area that contains sensors to indirectly measure the laser light intensity delivered by each fiber optic bundle. This intermediary element allows monitoring of bundle integrity without directly interfering with the welding process
2Manufacturing precision
If laser light intensity is not monitored and adjusted, then the system operation is simple, but the weld quality becomes inconsistent and sensors may be damaged
Solution Approach 1:
The controller receives feedback signals from sensors that detect laser light intensity at the weld area and automatically adjusts laser channel outputs to maintain consistent intensity levels, ensuring repeatable weld quality while protecting sensors from damage through intensity control
Solution Approach 2:
The system performs preliminary monitoring of laser light intensity before welding operations commence, allowing detection of bundle integrity issues in advance and prevention of potential sensor damage or poor weld quality
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 ensures consistent laser light intensity at the weld area, preventing damage to sensors and maintaining weld quality by automatically adjusting laser channel outputs, thereby enhancing the reliability and accuracy of the welding process.
Implementation Method 1
sensing the laser light from each fiber optic bundle with the laser light intensity sensor of the smart part corresponding to the fiber optic bundle
Implementation Method 2
Waveguide 30 homogenizes the laser energy delivered to work pieces 60 through each laser delivery optical fiber
Data Source
AI summary
A method for sensing intensity of laser light in a simultaneous laser welding system includes placing a smart part in a weld area. The smart part includes at least a laser light intensity sensor for sensing laser light directed at it. Laser light intensity is sensed by the laser light intensity sensor of the smart part which provides an output signal indicative thereof to a controller.