Laser Weld Bridging Molten Pool for Gap-Tolerant Metal Joining
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Solution Overview
Problem
Current laser welding methods require preprocessing to correct differences in level and gaps between metallic members, increasing manufacturing labor, time, and cost.
Innovation Solution
A streamlined laser welding method and device that form a bridging molten pool by emitting laser light to the end portions of metallic members, allowing for efficient welding without the need for preprocessing, using a laser welding device with a light source and optical head to create a molten pool that bridges over the end portions and solidifies, reducing labor, time, and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preprocessing is performed to correct differences in level and gaps between metallic members, then welding quality is improved, but manufacturing labor and time increase
Solution Approach 1:
The laser welding process itself compensates for level differences and gaps between metallic members through the formation of a bridging molten pool. The system uses real-time detection of relative positional relations and adjusts laser irradiation accordingly, allowing the welding process to self-correct alignment issues without requiring external preprocessing operations.
Solution Approach 2:
The invention changes the laser irradiation parameters (position, intensity, duration) based on detected relative positional relations between members. By dynamically adjusting these parameters, the system maintains high welding quality despite variations in member alignment, eliminating the need for preprocessing to standardize positions.
2Manufacturing precision
If preprocessing is performed to correct differences in level and gaps between metallic members, then welding quality is improved, but manufacturing cost increases
Solution Approach 1:
The laser welding system performs self-alignment compensation by detecting relative positional relations and automatically adjusting irradiation parameters. This eliminates the need for separate preprocessing operations, reducing manufacturing complexity and cost while maintaining high welding quality.
Solution Approach 2:
The invention replaces mechanical preprocessing operations (such as physical alignment tools or fixtures) with an optical detection and control system. The laser detection system measures relative positions and the control system adjusts irradiation parameters accordingly, substituting complex mechanical alignment procedures with a more efficient optical-mechanical integrated system.
3Productivity
If laser light is emitted to form a bridging molten pool without preprocessing, then manufacturing efficiency is improved, but welding quality may deteriorate
Solution Approach 1:
The system implements a feedback mechanism where the detection unit measures the relative positional relation between metallic members, and the control unit adjusts laser irradiation parameters based on this feedback. This closed-loop control ensures that welding quality is maintained even when members are not pre-aligned, allowing direct welding without preprocessing while preserving high manufacturing quality.
Solution Approach 2:
The invention employs dynamic adjustment of laser irradiation parameters during the welding process based on real-time detection of member positions. Rather than requiring static pre-alignment, the system adaptively modifies irradiation conditions to compensate for positional variations, enabling efficient direct welding while maintaining consistent weld quality.
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 method and device enable faster and more efficient welding of metallic members, reducing preprocessing needs and associated costs, while ensuring strong and efficient connections between the members.
Implementation Method 1
forming a first molten pool protruding from the first end portion toward at least the second end portion, by emitting laser light to the first end portion
Implementation Method 2
forming a first molten pool protruding from the first end portion toward at least the second end portion, by emitting laser light to the first end portion
Implementation Method 3
an optical head configured to emit the laser light from the light source
Data Source
AI summary
A laser welding method includes: preparing a first member and a second member, the first member and the second member having a first end portion and a second end portion in a first direction, respectively; arranging the second member adjacent to the first member in a second direction intersecting with the first direction such that a distance between the first end portion and the second end portion is 0 or more along the first direction; forming a first molten pool protruding from the first end portion toward at least the second end portion, by emitting laser light to the first end portion; forming a bridging molten pool by emitting laser light to at least the first end portion after the forming of the first molten pool, the bridging molten pool bridging over the first end portion and the second portion; and solidifying the bridging molten pool.