Automated Laser Strip Splicing Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for laser strip splicing are labor-intensive, complex, and often fail to produce high-quality welds, especially for thin metals, requiring manual alignment and skilled operators, and are not efficient for producing longer spools of metal strips.
Innovation Solution
A mobile laser strip splicing apparatus with a graphical user interface that automates the welding process, capable of handling metals from 0.00508 to 0.127 cm thick and 0.3175 to 35.56 cm wide, featuring a fiber laser for cutting and welding, and optional annealing units to prevent brittleness, ensuring minimal protrusion and lateral misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If GTAW welding process is used to weld metal strips, then welding capability is achieved, but the process becomes labor intensive and complex
Solution Approach 1:
The patent replaces the manual GTAW welding process with an automated laser welding system. The laser welding apparatus automatically positions and welds the metal strips without requiring manual operation, thereby reducing labor intensity and operational complexity while maintaining welding capability.
Solution Approach 2:
The laser welding system is designed to automatically perform welding operations without continuous human intervention. The system self-regulates the welding process, including positioning, welding parameter control, and quality assurance, eliminating the need for skilled operators and complex manual procedures.
2Reliability
If GTAW welding is used for thin metal strips, then welding can be performed, but multiple attempts are required before obtaining an acceptable weld
Solution Approach 1:
The patent replaces GTAW with laser welding technology that provides precise energy delivery and better control over the welding process. This substitution enables successful welding of thin metal strips in a single pass by accurately controlling heat input and weld parameters, eliminating the need for multiple retry attempts.
3Reliability
If laser based systems are used to weld thin metal strips, then welding capability down to 0.01016 cm thickness is achieved, but the process becomes very time consuming
Solution Approach 1:
The patent implements dynamic control of the laser welding process, including real-time adjustment of welding speed, power, and focal position. This dynamic optimization allows the system to adapt to different metal thicknesses and conditions, achieving high-quality welds on thin materials without requiring excessively slow processing speeds.
Solution Approach 2:
The system automatically adjusts welding parameters such as laser power, scanning speed, and focal depth based on the detected metal thickness and material properties. These parameter optimizations enable efficient welding of thin strips by minimizing heat input time while ensuring complete penetration and sound weld quality.
4Reliability
If laser based systems are used for welding, then welding capability is improved, but edge conditioning and alignment become critical and difficult to use
Solution Approach 1:
The patent replaces manual edge conditioning and alignment procedures with automated laser-based systems that include integrated positioning and sensing capabilities. The system automatically compensates for minor misalignments and performs edge preparation through laser processing, eliminating the need for precise manual alignment and reducing operational difficulty.
Solution Approach 2:
The laser welding system incorporates self-aligning and self-conditioning capabilities through automated sensing and control mechanisms. The system automatically detects edge positions, adjusts welding parameters, and performs necessary edge preparation without requiring operator skill or manual intervention, thereby simplifying operation.
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 apparatus enables the production of high-quality, automated welds across a wide range of metal thicknesses and widths, reducing operator skill requirements and increasing efficiency by minimizing manual intervention and ensuring consistent weld quality.
Implementation Method 1
a laser device for both cutting said downstream and upstream metal strips
Implementation Method 2
a laser device for both cutting said downstream and upstream metal strips and for welding said metal strips together
Implementation Method 3
optional annealing units to prevent brittleness
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A splicing apparatus (10) for joining a trailing end of a downstream metal strip to the leading end of an upstream metal strip includes a base (14) having a working surface, a cover assembly (16) operatively connected to the base (14) and movable between an open position and a closed position, a fixed platen fixedly secured to the working surface, a moving platen slidably connected to the working surface, and a laser device housed in the cover assembly for both cutting said downstream and upstream metal strips and for welding said metal strips together, the laser device including a laser source and a laser head in communication with the laser source, the laser head being connected to said cover assembly.