Ring Nozzle Air Vortex for Laser Welding Spatter Protection

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Solution Overview

Problem

Laser welding devices face high energy and maintenance costs due to the need for compressed air to create an air curtain for spatter protection, which is inefficient and costly, and can lead to contamination of the welding optics.

Innovation Solution

The spatter protection device features an outlet gap with swirl blades that directs air radially onto the axis of the welding optics, creating an axial air vortex to counteract spatter and gases, using a blower instead of compressed air, reducing energy consumption and installation costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If compressed air is used to create an air curtain for spatter protection, then the welding optics are protected from contamination, but energy consumption and maintenance costs increase significantly

Engineering Contradiction:

Improveprotection of welding opticsVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical compressed air system with a gas flow generated by a simple blower or even natural convection currents. The gas flow is directed through a nozzle arrangement that creates an air curtain without requiring high-pressure compressed air, thus substituting a complex mechanical system with a simpler alternative that achieves the same protective function with lower energy consumption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the parameters of the gas flow system by using low-pressure blowers instead of high-pressure compressed air systems. The inlet pressure is reduced from 500-1000 kPa to much lower values, and the air flow rate is optimized to several thousand standard liters per minute through careful nozzle design, achieving effective spatter protection with significantly reduced energy input

Inventive Principle:

Principle #35Parameter changes

2Reliability

If compressed air system is implemented for spatter protection, then welding optics are protected, but installation and maintenance costs increase

Engineering Contradiction:

Improveprotection of welding opticsVSAvoidinstallation and maintenance costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the complex compressed air infrastructure with a simple blower system or natural convection setup. This substitution eliminates the need for expensive compressed air generators, storage tanks, and distribution networks, thereby dramatically reducing both installation and ongoing maintenance costs while maintaining effective spatter protection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs simple, inexpensive nozzle components that can be easily manufactured and replaced if needed. The nozzle arrangement uses basic aerodynamic principles rather than complex mechanical parts, making the system more cost-effective in terms of both initial installation and long-term maintenance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If high air flow is used to create air curtain, then spatter protection is effective, but energy consumption increases

Engineering Contradiction:

Improvespatter protection effectivenessVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent optimizes the air flow parameters by using a carefully designed nozzle arrangement that directs gas flow radially inward and obliquely toward the workpiece. The exit gap geometry and swirl vane configuration create a vortex flow pattern that maintains effective spatter protection with lower air flow rates compared to conventional perpendicular air knife designs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes vortex flow dynamics and radial gas flow patterns to create an effective air curtain. The swirl vanes generate a rotating gas flow that adheres to the workpiece surface and effectively deflects spatter, utilizing aerodynamic principles to achieve better protection efficiency with reduced energy input

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 effectively prevents spatter and gases from reaching the optics with significantly lower air throughput and pressure, reducing energy costs by up to 90% and eliminating the need for flexible air lines, enhancing the precision and maintenance of the welding head.

Implementation Method 1

the air flow is deflected into an air vortex directed axially towards the workpiece

Methodology Applied

Scientific EffectVortex flow: Vortex Ring

Implementation Method 2

the high energy density of the laser beam often leads to the formation of weld spatter

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentEP3098019B1Laser welding device with splash protection device

Publication Date: 2024.09.25 BERGMANN UWE

Figure 1~2
Figure 3

AI summary

Laser welding device with a welding optic (14) for beam shaping of a laser beam (16) directed towards a workpiece (18), and with a splash guard in the form of a nozzle (28) for generating an airflow (42) in a space between the welding optic (14) and the workpiece (18), characterized in that the nozzle (28) surrounds the laser beam (16) in a ring shape and forms an exit gap (34) extending radially inwards and obliquely towards the workpiece (18).