Handheld Laser Welding Torch Control for Safer, Easier Welds
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Solution Overview
Problem
Conventional laser welding systems pose challenges for new users, particularly in achieving quality welds and incorporating laser protection features, as they differ significantly from arc-related welding systems.
Innovation Solution
A manually operated laser welding system with a controller that regulates laser power based on user and sensor inputs, employing wobble movements and optics to control the laser beam, and a wire heater to preheat the electrode wire, allowing for precise control of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser welding systems are used, then welding speed and precision are improved, but ease of operation deteriorates for new users
Solution Approach 1:
The system provides automatic laser protection features that activate without user intervention, and includes integrated training modes that automatically guide new users through welding procedures, allowing the system to serve itself in protecting users and teaching operations
Solution Approach 2:
The control system acts as an intermediary between the user and the complex laser welding parameters, providing simplified interfaces and automated parameter selection that mediates the complexity while maintaining precise welding control
2Object-affected harmful factors
If laser protection features are incorporated, then safety is improved, but device complexity increases
Solution Approach 1:
Multiple laser protection functions (interlock systems, emergency stop, over-temperature protection, motion-sensitive shut-off) are merged into a single integrated control system that manages all safety features through unified circuitry and software
Solution Approach 2:
The control system is designed with multi-functionality to handle both welding control and multiple types of laser protection simultaneously, allowing a single system to perform diverse functions without requiring separate dedicated devices for each protection type
3Temperature
If wobble movements are applied to control laser beam, then heat distribution is improved, but manufacturing precision requirements increase
Solution Approach 1:
The laser beam control system transitions from static positioning to dynamic wobble movements, allowing the beam to oscillate in controlled patterns that distribute heat more effectively across the weld area while maintaining precise overall control through coordinated motion
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 enhances weld quality and user experience by providing precise control over heat input and distribution, improving filler mixing and penetration profiles, and integrating safety features for effective laser protection.
Implementation Method 1
a laser source to generate laser power to perform a welding operation
Implementation Method 2
a wire heater to preheat the electrode wire
Data Source
AI summary
Systems and methods for laser welding are disclosed. A laser welding system includes a manually operated laser welding torch to direct laser power to a workpiece to generate a puddle during a laser welding operation. The welding system includes a controller to regulate activation and regulation of the laser power based on user inputs, sensor inputs, and/or synergic control of a laser power source.