Laser Remote Processing Fillet Welding Path Correction
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Solution Overview
Problem
Laser remote processing of workpieces on fillets faces challenges due to high precision requirements, leading to variations in the laser beam's path, resulting in welding errors and reduced seam quality, especially in end fillet welds between metal sheets with varying gap widths and coatings.
Innovation Solution
The method involves optical monitoring using illuminating radiation and image capturing units to evaluate the laser beam's position and fillet geometry, allowing for automatic correction of the laser beam's path to maintain precise alignment and focus, ensuring reliable edge recognition and seam quality through adaptive beam adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser remote processing is used to increase processing speed and working area, then productivity is improved, but positioning precision deteriorates due to large working distance
Solution Approach 1:
The patent implements an optical feedback system using image capturing units that continuously monitor the laser beam position on the workpiece. The control device processes the captured images and automatically adjusts scanner device parameters to correct positioning deviations in real-time, thereby maintaining manufacturing precision while enabling remote processing for high productivity
Solution Approach 2:
The patent replaces mechanical positioning adjustment with an optical monitoring and control system. Instead of mechanically adjusting the scanner device to maintain precision, the system uses optical feedback from image capturing units to detect position deviations and automatically corrects them through electronic control of the scanner device
2Manufacturing precision
If automatic path correction is implemented to improve positioning precision, then manufacturing precision is improved, but device complexity increases due to additional monitoring and control systems
Solution Approach 1:
The patent employs a multi-functional control device that integrates image processing, position calculation, and scanner device control into a single system. The control device simultaneously performs multiple functions: processing images from capture units, calculating optimal laser beam paths, and adjusting scanner device parameters, thereby reducing overall system complexity through functional integration
3Manufacturing precision
If optical monitoring is added to correct laser path, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the optical monitoring function with the existing control device. The image capturing units are integrated into the control system, and the control device processes the optical data alongside other control parameters. This merging of functions into a unified control architecture minimizes the increase in device complexity while achieving improved edge recognition accuracy
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 significantly improves process stability and quality by preventing welding errors, maintaining zero-gap connections, and compensating for component tolerances, making it suitable for mass production in vehicle bodywork construction.
Implementation Method 1
The working range of the laser beam on the workpiece is illuminated by illuminating radiation and is detected by at least a first image capturing unit
Implementation Method 2
The scanner device can have lens systems for focusing of the laser beam
Implementation Method 3
a laser beam can be deflected by means of at least one movable mirror and positioned on or guided over the workpiece to be processed
Data Source
AI summary
The invention relates to a method for laser remote processing of a component on a fillet, wherein a laser beam is directed by means of a scanner device onto the component and guided over said component. The working range of the laser beam on the workpiece is illuminated with illuminating radiation and is captured by at least one image capturing unit. The illuminating radiation is directed onto the component at an angle of attack which is set depending the fillet geometry of the component. The captured image data are evaluated automatically and, with the aid of the evaluation, if appropriate, an automatic correction of the path of the laser beam is carried out.