Laser Welding Airflow Layout for Spatter and Fume Removal
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Solution Overview
Problem
Existing laser welding apparatuses face challenges in efficiently removing spattering and fumes from the optical path of the laser beam, which can interfere with the welding process and reduce precision.
Innovation Solution
A laser welding apparatus equipped with an airflow forming unit that generates sheet-shaped airflows, utilizing the Coandă effect to increase air volume and effectively remove spattering and fumes by positioning emission nozzles along the optical path to create a synergistic airflow that enhances airflow volume and captures dust using a filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple nozzles emit airflows at different pressures parallel to the protection glass surface, then spattering and fumes are removed from the optical path, but the device complexity increases due to the need for deflector plates and multiple nozzles
Solution Approach 1:
The airflow forming unit is divided into multiple nozzles (first and second nozzles) that emit airflows at different pressures. This segmentation allows each nozzle to contribute differently to the overall airflow pattern, creating effective spattering and fume removal while maintaining a relatively simple structure without deflector plates
Solution Approach 2:
The invention uses pneumatic principles by emitting airflows at different pressures from multiple nozzles. The first nozzle emits airflow at a higher pressure while the second nozzle emits at a lower pressure, creating a combined airflow pattern that effectively removes spattering and fumes from the optical path
2Ease of operation
If a deflector plate is added to redirect airflows back toward the nozzles, then airflow direction is controlled, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of using a deflector plate to redirect airflows back toward the nozzles (the conventional approach), the invention inverts the approach by positioning the nozzles themselves to emit airflows in the desired directions. The first and second nozzles are arranged to emit airflows at different pressures directly toward the optical path, eliminating the need for deflector plates and simplifying manufacturing
3Manufacturing precision
If airflow volume is increased to improve spattering and fume removal, then welding precision improves, but energy consumption increases
Solution Approach 1:
The invention applies local quality by emitting airflows at different pressures from different nozzles at different positions along the optical path. The first nozzle emits at higher pressure where spattering is most severe, while the second nozzle emits at lower pressure in regions where less aggressive airflow is needed. This localized differentiation achieves effective spattering and fume removal while optimizing energy consumption
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 solution reliably removes spattering and fumes from the optical path, improving the precision and efficiency of the welding process by increasing airflow volume and capturing dust without the need for additional dust collection devices.
Implementation Method 1
utilizing the Coandă effect to increase air volume and effectively remove spattering and fumes
Data Source
AI summary
A laser welding apparatus is equipped with a laser head that emits a laser beam and an airflow forming unit that forms sheet-shaped airflows, in which the airflows formed by the airflow forming unit traverse an optical path of the laser beam emitted from the laser head, the airflows traversing the optical path at multiple positions which are spaced from each other in a direction along the optical path in a same direction. The airflow forming unit has an opening between the airflows at the multiple positions, the opening penetrating in a direction in which the airflows traverse the optical path.