Laser Weld Head Rotary Vertical Movement for Contour Tracking
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Solution Overview
Problem
Existing welding machines with vertical laser welder movements are insufficient for producing satisfactory welds on workpieces with varying heights and slopes, as the points of maximal engagement are not always in the vertical plane of the laser welders.
Innovation Solution
A welding machine with a laser weld head capable of both rotary and vertical movements to enhance the formation of welded seams on workpieces with varying profiles, allowing for simultaneous production of welds on opposite sides and maintaining uniform pressure through a system of rolls and hydraulic cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single vertical movement mechanism is used for the laser weld head, then the device complexity is reduced, but the welding precision deteriorates because the weld point cannot match the varying contour of the workpiece
Solution Approach 1:
The welding system is divided into multiple independent movement mechanisms: a vertical movement mechanism for height adjustment and a rotary movement mechanism for angular positioning. This segmentation allows each mechanism to independently control a specific degree of freedom, enabling the laser weld head to precisely follow complex three-dimensional workpiece contours that cannot be achieved with a single vertical movement mechanism alone.
Solution Approach 2:
The invention transitions from two-dimensional vertical movement to three-dimensional positioning by adding rotary movement capability. The laser weld head can now move not only vertically up and down but also rotate around the workpiece axis, creating a spherical coordinate system for positioning. This dimensional expansion enables precise welding on surfaces with varying heights and slopes.
2Ease of operation
If the laser weld head only moves vertically, then the ease of operation is improved, but the adaptability deteriorates because it cannot accommodate workpieces with varying heights and slopes
Solution Approach 1:
The welding system employs dynamic, adjustable movement mechanisms rather than fixed positioning. The vertical movement mechanism allows the laser weld head to adjust its height dynamically along the workpiece length, while the rotary movement mechanism enables real-time angular adjustment to match local surface slopes. This dynamic adaptability allows the system to accommodate varying workpiece profiles without requiring complex reconfiguration or manual intervention.
3Manufacturing precision
If multiple independent welders are used to cover varying workpiece contours, then the welding precision is improved, but the device complexity increases
Solution Approach 1:
The laser weld head is designed as a multi-functional device capable of performing welding operations on various workpiece profiles through combined vertical and rotary movements. Rather than requiring separate specialized welders for different contour types, this universal weld head can adapt to flat, curved, sloped, and irregular surfaces by coordinating its two degrees of freedom, thereby achieving precise welding on diverse geometries with a single device.
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 ensures consistent and satisfactory welds on workpieces with non-uniform heights and slopes by allowing precise adjustment of the weld point to match the contour of the workpiece, maintaining seam integrity and security throughout the welding process.
Implementation Method 1
a first laser welder (200) and a second laser welder (202) positioned side-by-side and arranged to move in unison with the pinch roll (56)
Implementation Method 2
maintaining seam integrity and security throughout the welding process
Data Source
AI summary
Weld seams that vary in height along the lengths of a pair of workpieces are produced using at least one laser weld head mounted for vertical and rotary movements to accommodate differences in the vertical heights and contours of seam lines along which the weld seams are to be formed.