Handheld Laser Welding Torch Activation Using Pressure and Proximity
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Solution Overview
Problem
Handheld laser devices face issues with accidental emission of laser light into unintended directions, and there is a need for performance improvements in welding and cutting procedures.
Innovation Solution
A laser welding system that includes a controller, a pressure sensor, and a proximity sensor to ensure the laser light is only activated when the handheld torch is properly positioned against a workpiece, using a pressure threshold and proximity signals to prevent unwanted laser emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser light is activated without position verification, then the operational efficiency is improved, but the safety deteriorates due to accidental emission into unintended directions
Solution Approach 1:
The system performs preliminary verification of torch position and pressure conditions before activating the laser light. The controller checks if the torch is properly positioned against the workpiece and if sufficient pressure is applied, ensuring safety conditions are met before laser emission occurs.
Solution Approach 2:
The system uses sensors to continuously monitor torch position and pressure levels, providing feedback to the controller. The controller receives signals from the proximity sensor and pressure sensor, and only activates the laser when both conditions indicate proper positioning and sufficient pressure.
2Object-affected harmful factors
If position verification sensors are added to the system, then the safety is improved, but the device complexity increases
Solution Approach 1:
The proximity sensor serves multiple functions: it detects whether the torch is near the workpiece, verifies proper positioning, and prevents accidental emission. The pressure sensor both measures applied pressure and serves as a position verification mechanism, reducing the need for separate dedicated sensors.
Solution Approach 2:
The controller acts as an intermediary that processes signals from simple sensors and makes the decision to activate or prevent laser emission. This centralizes the safety logic in software/control algorithms rather than requiring complex hardware interlocks.
3Object-affected harmful factors
If the laser activation conditions are made more stringent, then the safety is improved, but the productivity decreases due to additional verification steps
Solution Approach 1:
The sensors continuously monitor torch position and pressure levels during the welding process. Once the laser is activated, the system maintains continuous verification without interrupting the welding operation, ensuring safety while maintaining productivity.
Solution Approach 2:
The system automatically verifies positioning and pressure conditions without requiring manual confirmation or additional operator actions. The sensors and controller work together to self-verify safety conditions, eliminating steps that would slow down the welding process.
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 prevents accidental laser emission and ensures precise activation of the laser light only when the torch is adjacent to the workpiece, enhancing safety and operational efficiency in welding and cutting processes.
Implementation Method 1
a pressure sensor that measures a pressure level applied to the nozzle and generates a corresponding pressure level signal
Implementation Method 2
a proximity sensor that is operatively connected to the sense lead and the handheld laser welding torch and that is configured to determine whether the handheld laser welding torch is adjacent to the workpiece and generate a corresponding proximity signal
Implementation Method 3
a laser power supply having a controller that controls activation of laser light by the laser power supply
Data Source
AI summary
A laser welding system includes a laser power supply having a controller that controls activation of laser light by the power supply. A sense lead is attachable to a workpiece. A handheld laser welding torch is connected to the power supply to receive the laser light. The torch includes a nozzle having an electrically insulating outer surface, and a pressure sensor that measures a pressure level applied to the nozzle and generates a pressure level signal. A proximity sensor is operatively connected to the sense lead and the torch and is configured to determine whether the torch is adjacent to the workpiece and generate a proximity signal. The controller receives the pressure level signal and the proximity signal. The controller activates the laser light when the pressure level applied to the nozzle meets or exceeds a threshold and the proximity signal indicates that the torch is adjacent to the workpiece.