Handheld Laser Welder Control With Feedback and Safety Interlocks
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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, making it difficult for those familiar with arc-related welding systems to adapt effectively.
Innovation Solution
A manually operated laser welding system with a controller that regulates laser power based on user and sensor inputs, incorporating a handheld torch with laser reflection covers, fans for protection, and galvanometers for precise beam control, along with a wire feeder system to facilitate efficient welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
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 automatically performs functions such as laser protection activation, parameter adjustment, and welding process control without requiring manual intervention from the operator. The controller autonomously manages laser power regulation, galvanometer coordination, and safety feature activation based on sensor inputs and pre-programmed parameters, allowing new users to operate the system without extensive training while maintaining high welding speed and precision
Solution Approach 2:
The system incorporates sensors that continuously monitor welding parameters, laser beam position, and process conditions. This feedback is processed by the controller to automatically adjust laser power, wire feed rate, and galvanometer movement in real-time, ensuring consistent weld quality and maintaining protection features without requiring manual adjustment by the operator
2Object-affected harmful factors
If laser protection features are incorporated, then safety is improved, but device complexity increases
Solution Approach 1:
The laser protection features are integrated into the existing welding system architecture rather than added as separate standalone components. The controller combines laser power regulation, safety interlocks, sensor monitoring, and galvanometer control into a unified system that manages both welding operations and protection features through a single coordinated interface, reducing overall system complexity while maintaining comprehensive safety
Solution Approach 2:
The controller acts as an intermediary between the laser source, galvanometers, wire feeder, and safety sensors. It coordinates all components and automatically manages protection features such as laser shutdown sequences and safety interlocks based on sensor inputs, eliminating the need for complex manual safety systems while ensuring comprehensive operator and equipment protection
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 enables precise control of laser power and protection features, allowing users to achieve high-quality welds with improved safety and flexibility, particularly in complex joint welding and additive manufacturing processes.
Implementation Method 1
Laser welding is a welding technique used to join multiple pieces of metal through the use of a laser. The laser beam provides a concentrated heat source
Implementation Method 2
galvanometers for precise beam control
Data Source
AI summary
Systems and methods for laser welding are disclosed. A laser welding system includes a hand held laser welding tool to direct laser power to a workpiece to generate a weld 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 system.