Laser Seam Stepper Airflow Layout for Debris-Free Welding
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Solution Overview
Problem
Conventional laser welding systems face challenges in protecting focusing optics from debris, maintaining weld quality, and accurately positioning pieces with complex geometries, leading to inefficiencies and potential damage to the protective window and inconsistent seam quality.
Innovation Solution
The hand-maneuverable seam stepper employs an overjet air delivery technique to prevent debris from reaching the protective window, uses a light detector for real-time adjustment of laser power based on seam quality, and features pneumatically and electrically operated arms to automatically adjust the position of pieces for precise alignment and pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cross-jet air supply technique is used to protect focusing optics from debris, then the protective window is protected from debris, but vortexes are generated causing pressure gradient that deteriorates laser beam quality and allows debris to flow towards the protective window
Solution Approach 1:
The patent inverts the conventional cross-jet technique by using an axial air jet directed from the welding zone towards the protective window, rather than a perpendicular cross-jet. This reversal of air flow direction eliminates vortex formation and pressure gradients while maintaining debris protection, thereby preserving laser beam quality.
Solution Approach 2:
The patent changes the parameters of air supply by directing the air jet axially parallel to the optical axis rather than perpendicularly. This parameter change in air flow direction eliminates the harmful vortexes and pressure gradients generated by cross-jet while maintaining the protective function against welding debris.
2Productivity
If high power laser beam is used for welding, then welding speed increases, but the beam may melt all overlaid pieces forming through-going opening instead of joining them
Solution Approach 1:
The patent employs a feedback control system using a light detector to monitor the laser beam intensity transmitted through the workpieces. The detected light intensity provides real-time feedback to adjust laser power, preventing excessive melting that would create through-going openings while maintaining high welding speed.
Solution Approach 2:
The patent uses partial action by dynamically adjusting laser power based on real-time monitoring. Instead of applying full high power continuously, the system applies only the necessary power level detected through feedback, preventing over-melting while maintaining efficient welding throughput.
3Ease of operation
If manual positioning is used for complex geometry pieces, then positioning can be adjusted, but the operation is imprecise and time consuming
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated robotic system equipped with sensors and control algorithms. This substitution eliminates the imprecision and time consumption of manual positioning while maintaining the ability to adjust to complex geometries through automated detection and adaptation.
4Manufacturing precision
If robot is displaced to predetermined position, then welding location is correct, but manipulation is required to correct position between pieces and robot
Solution Approach 1:
The patent implements self-service positioning where the robotic system automatically detects and corrects position misalignments between itself and the workpieces using sensors and feedback control. This eliminates the need for external manual manipulation while maintaining precise welding location 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 solution extends the life of the protective window, maintains beam quality, ensures consistent weld quality by adjusting power in real-time, and automates the positioning process, reducing manual intervention and increasing efficiency in robotic laser welding.
Implementation Method 1
an overjet air delivery technique to prevent debris from reaching the protective window
Implementation Method 2
uses a light detector for real-time adjustment of laser power based on seam quality
Implementation Method 3
the sharp focusing and high energy concentration of a laser beam provides faster welding
Implementation Method 4
features pneumatically and electrically operated arms to automatically adjust the position of pieces
Data Source
Figure 1
Figure 2A~2C
Figure 3A~4C
AI summary
A robotically operated laser seam stepper is configured with an elongated support column extending along a longitudinal axis and made from lightweight material. A support plate is displaceably mounted to the column while supporting thereon an optical head which is provided with optics. The optics is configured to direct a laser beam along a path towards a welding zone through a protective window of the optical head. The laser seam stepper further is structured with a first arm mounted to the support plate and extending along a longitudinal axis of the stepper diametrically opposite to the optical head. The inner surface of the displaceable arm defines a tunnel which is aligned with the optical head and axially traversed by the laser beam, a first axially flowing stream of pressurized gaseous medium, and by a second axially flowing stream of gaseous medium. The second stream, entering the tunnel at a pressure lower than that one of the first stream in response to a pressure gradient generated in the column, does not generate vortexes within the column. The first and second streams exit through the downstream end of the tunnel next to the welding zone. As the streams flow out, they carry out welding debris from the tunnel.