Laser Welding Feedback Control for In-Process Defect Repair
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Solution Overview
Problem
Existing laser welding technologies lack effective measures for quickly addressing unacceptable welding defects during high-speed scanning welding, leading to increased production costs and reduced efficiency due to the need for post-welding repair and rework.
Innovation Solution
A laser welding device and method that includes a detector for identifying welding defects and a controller to perform supplementary laser welding at predetermined positions near the defects, ensuring rapid maintenance of welding strength by condensing laser light and controlling the welding process based on real-time detection signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed scanning welding is performed, then productivity is improved, but welding quality deteriorates due to increased sensitivity to variations in dimensions, surface state, and welding conditions
Solution Approach 1:
The patent implements real-time monitoring of welding parameters (laser power, welding speed, focal position) and workpiece characteristics (surface state, dimensions) during the welding process. When deviations are detected, the system automatically adjusts parameters to maintain welding quality, enabling high-speed scanning welding without sacrificing reliability
Solution Approach 2:
The patent performs preliminary measurements and assessments of workpiece dimensions, surface state, and material properties before welding begins. Based on these preliminary data, optimal welding parameters are pre-calculated and set, allowing high-speed welding to proceed with predetermined quality assurance
2Reliability
If welding defects are detected and repaired after welding completion, then welding quality is improved, but productivity deteriorates due to additional time and labor required for repair
Solution Approach 1:
Real-time defect detection during welding allows immediate corrective action rather than post-welding repair. The system monitors welding parameters and workpiece conditions continuously, detecting defects as they occur and triggering automatic adjustments or rework at the specific location, thereby maintaining quality while avoiding complete production shutdown
Solution Approach 2:
The system performs preliminary defect detection and assessment during the welding process itself, allowing corrective measures to be taken before the welding operation is fully completed. This prevents the need for separate post-welding inspection and repair operations
3Reliability
If supplementary laser welding is performed at defect locations, then welding quality is improved, but productivity deteriorates due to additional welding operations
Solution Approach 1:
The patent applies supplementary welding only at specific localized defect areas rather than re-welding entire joints. The system precisely identifies defect locations and concentrates additional laser energy only where needed, maintaining welding strength at problematic areas while minimizing additional processing time
Solution Approach 2:
The system pre-identifies defect locations during the primary welding process and plans supplementary welding operations in advance, allowing for efficient sequencing and execution of repair operations without significant disruption to the overall welding schedule
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 approach allows for immediate correction of welding defects, reducing overall production time and improving efficiency by enabling continuous laser welding without the need for extensive post-processing repairs.
Implementation Method 1
a laser oscillator 80 to which an incidence end of a fiber 90 is connectable; a welding head 30 connectable to an emission end of the fiber 90 and configured to perform laser welding while condensing laser light LB emitted from the laser oscillator 80 via the emission end of the fiber 90
Implementation Method 2
perform laser welding while condensing laser light LB emitted from the laser oscillator 80 via the emission end of the fiber 90 and irradiating the workpiece W with the condensed laser light LB
Data Source
AI summary
A laser welding device includes: a laser oscillator to which an incidence end of a fiber is connectable; a welding head connectable to an emission end of the fiber and configured to perform laser welding while condensing laser light emitted from the laser oscillator via the emission end and irradiating a workpiece with the laser light; a detector configured to detect presence or absence of a defect in the laser welding; and a controller including a processor and a memory storing instructions that, when executed by the processor, cause the laser welding device to perform operations. The operations include: performing, in response to receiving, from the detector, an output signal indicating a defect at a welding point on the workpiece during the laser welding of the workpiece, control such that supplementary laser welding is performed at a predetermined position in a vicinity of the welding point.