Laser Welding Head Motion for Complex Shapes and Cable Protection
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Solution Overview
Problem
Conventional laser welding apparatuses face challenges in miniaturization and handling large workpieces, particularly when performing complex shapes like annular or S-shapes, due to the need for large installation spaces and vulnerability of optical cables to physical forces and bending.
Innovation Solution
A laser machining apparatus with a moving mechanism that allows the laser head to move in a curved two-dimensional plane and rotate 360° around a rotational axis, combined with a hollow structural moving mechanism that synchronizes the laser light irradiation and welding filler feeding, ensuring precise control and minimizing stress on optical cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the laser head moves only in linear directions (X or Z) by rotating the workpiece, then the apparatus structure is simple, but it cannot perform complex shape machining (annular, S-shape) and requires large installation space
Solution Approach 1:
The patent transforms the static linear motion system into a dynamic multi-axis system. The laser head is equipped with not only X and Z linear motion mechanisms but also a rotational mechanism that enables the laser head to rotate around the workpiece center. This dynamic configuration allows the laser head to reach any position on the workpiece surface and perform complex shape machining while maintaining a compact apparatus structure.
Solution Approach 2:
The patent adds a rotational dimension to the traditional two-dimensional (X-Z) linear motion system. By enabling the laser head to rotate around the workpiece center, the system transitions from planar motion to three-dimensional spatial motion, allowing access to complex geometries such as annular and S-shaped patterns without requiring large installation space.
2Ease of operation
If the optical cable is subjected to bending and physical forces during laser head movement, then the apparatus can achieve flexible positioning, but the optical cable becomes vulnerable to damage
Solution Approach 1:
The patent introduces a rotational mechanism as an intermediary between the linear motion system and the laser head. This intermediate structure provides a controlled rotation path for the optical cable, reducing abrupt bending and physical stresses. The optical cable is routed through the rotational mechanism in a manner that minimizes stress concentration and prevents damage while maintaining positioning flexibility.
Solution Approach 2:
The patent employs flexible cable management structures that allow the optical cable to bend smoothly during laser head rotation and positioning. These flexible components accommodate the dynamic motion of the laser head while protecting the optical cable from excessive bending stresses and physical damage, ensuring both operational flexibility and cable reliability.
3Area of stationary object
If the apparatus is miniaturized to reduce installation space, then the footprint is reduced, but handling large workpieces and maintaining precision becomes difficult
Solution Approach 1:
The patent employs dynamic multi-axis motion mechanisms that enable a compact apparatus to handle large workpieces effectively. The laser head can rotate around the workpiece center and access distant positions through coordinated linear and rotational motions, allowing miniaturized apparatus to process large workpieces with the same precision as larger systems would provide.
Solution Approach 2:
By adding the rotational dimension to the motion system, the patent enables a compact apparatus footprint to achieve large working envelope. The laser head can reach positions that would otherwise require a much larger linear motion system, allowing miniaturization while maintaining the capability to handle large workpieces and perform complex shape machining.
4Adaptability or versatility
If the laser head rotates 360° around the workpiece, then complex shapes can be machined, but the optical cable and material handling become more complex
Solution Approach 1:
The patent merges the optical cable routing and material handling functions into the rotational mechanism structure. Both the optical cable and material supply lines are integrated through the same rotational joint, allowing coordinated management of both systems during 360° rotation. This unified approach reduces the overall complexity compared to having separate routing systems for optical and material components.
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 high-quality, uniform welding on large and complex workpieces without the need for extensive installation spaces, reducing the risk of optical cable damage and allowing for miniaturization of the apparatus while maintaining high precision and quality.
Implementation Method 1
a head (5) having an optical outlet from which laser light is output
Data Source
AI summary
A laser welding apparatus (1) includes a laser welding head (5) configured to irradiate a workpiece (10) with laser light, a welding filler feeding mechanism (6) configured to supply a welding material to a position on which laser welding is performed, and a hollow structural moving mechanism (100) configured to move a welding unit (50) including the laser welding head and the welding filler feeding mechanism. The hollow structural moving mechanism has an insertion portion (3a) through which an optical cable (41) of the laser welding head and a wire material (62) of the welding filler feeding mechanism are inserted.