Laser Head Timing Control for Precise Seam Welding
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Solution Overview
Problem
Laser welding apparatuses face challenges in maintaining precise control over the timing and speed of laser beam irradiation due to complex calculations required for real-time operation, leading to decreased precision and production efficiency.
Innovation Solution
A control apparatus that synchronizes the start and stop of the laser beam generation with the robot's acceleration phase, ensuring the laser head reaches a constant target speed before initiating beam emission, thereby improving timing accuracy and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the robot controller performs complicated prediction calculation in real time while the robot is operating, then the welding start position can be estimated, but the calculation does not keep up with the robot operation speed, causing timing control to become off and irradiation position precision to decrease
Solution Approach 1:
The patent applies preliminary action by pre-calculating the acceleration time required for the laser head to reach constant speed before welding starts. This acceleration time is calculated in advance based on the relationship between robot speed and laser head speed, rather than performing complex real-time prediction calculations during robot operation. This allows the system to maintain high robot speeds while ensuring accurate laser irradiation timing.
Solution Approach 2:
The patent replaces the complex real-time prediction calculation system with a simplified timing control system based on pre-calculated acceleration time. Instead of continuously calculating welding start positions based on robot position feedback during operation, the system uses a predetermined acceleration time parameter to determine when to start laser irradiation, significantly reducing computational burden while maintaining precision.
2Measurement precision
If the robot is operated at a low speed to maintain calculation accuracy, then the precision of position of irradiation can be maintained, but the production efficiency of the processed product decreases
Solution Approach 1:
The patent calculates the acceleration time in advance before robot operation begins. This pre-calculated acceleration time represents the period needed for the laser head to reach constant speed after the robot starts moving. By knowing this value beforehand, the system can operate the robot at high speed while accurately determining when to initiate laser irradiation, thus maintaining precision without sacrificing productivity.
3Reliability
If complex arithmetic processing is performed during robot operation, then timing control can be achieved, but the processing burden increases and efficiency decreases
Solution Approach 1:
The patent replaces complex real-time arithmetic processing with a simpler timing-based control system. The key insight is that the laser head speed is a fixed ratio of the robot speed, and the acceleration time can be pre-calculated based on this relationship. During operation, the system only needs to count the pre-determined acceleration time period to determine laser start timing, eliminating the need for continuous complex calculations and significantly reducing control 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 enhances the precision of laser seam welding by ensuring uniform heat input and accelerating production efficiency by reducing the need for complex arithmetic processing during robot operation.
Implementation Method 1
a light source configured to generate a laser beam, a laser head configured to emit the laser beam generated in the light source
Data Source
AI summary
A laser processing apparatus includes a light source, a laser head configured to emit a laser beam, a robot configured to move the laser head, and a control apparatus configured to control start and stop of generation of the laser beam and control operation of the robot. The control apparatus controls the light source to generate the laser beam when a first time has elapsed after causing the robot to start an operation of accelerating the laser head such that a movement speed of the laser head with respect to a processing target object reaches a constant target speed.