Laser Welding Nozzle Alignment for Variable Corner Shapes
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Solution Overview
Problem
Manufacturing errors, fixing errors, and temperature errors can lead to size variations in objects to be welded, causing laser beam positioning shifts during sequential welding, which requires time-consuming repositioning by a welder.
Innovation Solution
A laser welding system that includes a recognizing unit to identify the shape of the corner, a selecting unit to choose a nozzle matching the corner shape, and an attaching unit to attach the selected nozzle to the laser welding unit, allowing for automatic correction of laser beam positioning without welder intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If repositioning of the laser beam is performed for each object to correct positioning shifts, then welding precision is maintained, but productivity decreases due to time-consuming manual intervention
Solution Approach 1:
The system performs automatic positioning correction through image recognition and automated nozzle movement, eliminating the need for manual welder intervention. The welder simply places objects on the turntable, and the system autonomously detects corner positions, calculates beam shifts, and adjusts the nozzle accordingly to maintain welding precision.
Solution Approach 2:
The patent replaces manual mechanical positioning operations with an automated optical-mechanical system. Image recognition technology detects corner positions, and this information is processed to automatically control nozzle movement, substituting the welder's manual repositioning actions with an automated control system that integrates vision and motion control.
2Manufacturing precision
If manual repositioning by welder is performed, then positioning accuracy is maintained, but ease of operation deteriorates due to increased operational burden
Solution Approach 1:
The system autonomously performs all positioning correction tasks without requiring the welder to manually reposition the laser beam. The welder's role is simplified to merely placing objects on the turntable, while the system automatically detects positions, calculates corrections, and executes nozzle movements to maintain positioning accuracy.
Solution Approach 2:
The patent introduces an intermediary automated control system between the welder and the laser beam positioning process. This intermediary system includes image recognition technology that detects corner positions and a control unit that processes this information to automatically adjust nozzle position, thereby shielding the welder from complex positioning operations.
3Device complexity
If fixed nozzle shape is used, then device complexity is reduced, but adaptability decreases when welding different corner shapes
Solution Approach 1:
The system transitions from a static fixed nozzle configuration to a dynamic adaptable system. The nozzle can be automatically selected and positioned based on detected corner shapes, allowing the same welding system to adapt to different geometries (internal corners, external corners, various angles) without requiring complex manual reconfiguration.
Solution Approach 2:
The patent implements a universal nozzle selection system that can handle multiple corner types with a single welding apparatus. By providing a set of nozzles with different shapes and configurations, and automatically selecting the appropriate one based on detected corner geometry, the system achieves multi-functionality without requiring separate dedicated equipment for each corner type.
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
The system effectively corrects laser beam positioning shifts between objects of varying sizes, reducing the need for manual intervention and increasing welding efficiency by maintaining consistent beam alignment throughout the welding process.
Implementation Method 1
a laser welding system that welds a first plate-shaped member and a second plate-shaped member by a laser beam
Data Source
Figure 1
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Figure 4
AI summary
A shift in position of a laser beam used for welding objects is corrected without need for intervention by a welder. Irradiator (12) performs welding along a welding part of objects to be welded (60) by relatively moving objects to be welded (60) and nozzle (14) for emitting a laser beam. Arm apparatus (20) movably holds nozzle (14) while applying a biasing force to nozzle (14) in a direction toward the welding part such that nozzle (14) comes into contact with objects to be welded (60) to irradiate the welding part with the laser beam.