Laser Welding Device Fluid Clamping for Complex Contours
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Solution Overview
Problem
Existing laser transmission welding devices face challenges in achieving close mechanical contact along complex welding contours for non-flat workpieces, requiring complex and expensive clamping devices that are specific to each shape, making it difficult to maintain consistent pressure and quality across the entire welding process.
Innovation Solution
A laser transmission welding device utilizing a liquid flow to press workpieces together, where the fluid stream acts from a distance, allowing for adjustable and even clamping force distribution without direct mechanical contact, enabling flexible and efficient clamping of workpieces with varying shapes and contours, and incorporating a processing head with a movable outlet nozzle to align the fluid flow with the laser beam for precise pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex mechanical clamping devices are used to maintain close mechanical contact along complex welding contours, then welding quality is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical clamping devices with a fluid stream (gas or liquid) that acts on the workpieces to maintain close mechanical contact during laser transmission welding. The fluid stream eliminates the need for shape-specific mechanical clamps while providing uniform pressure distribution across the welding contour, thereby maintaining welding quality without increasing device complexity.
Solution Approach 2:
The patent utilizes pneumatic or hydraulic pressure through a fluid stream to apply clamping force on the workpieces. The fluid is directed through a nozzle system that follows the welding contour, providing adaptive pressure distribution without requiring complex mechanical clamping structures. This approach simplifies the overall device while maintaining precise pressure control for high-quality welding.
2Reliability
If shape-specific clamping devices are used for different workpiece shapes, then clamping effectiveness is improved, but adaptability decreases
Solution Approach 1:
The patent employs a universal fluid stream clamping system that can adapt to different workpiece shapes and welding contours without requiring shape-specific clamps. The fluid nozzle can be positioned and oriented to follow various contours, and the fluid pressure automatically adapts to the workpiece geometry, providing effective clamping for diverse shapes with a single versatile device.
Solution Approach 2:
The clamping system utilizes dynamic fluid flow that can be adjusted in pressure, direction, and positioning to match different workpiece geometries. The fluid stream naturally conforms to the workpiece surface and welding contour, providing adaptive clamping force distribution that maintains reliability across various shapes without requiring rigid, shape-specific mechanical structures.
3Force
If mechanical clamping devices are used to press workpieces together, then contact pressure is maintained, but ease of operation decreases
Solution Approach 1:
The patent replaces manual or mechanically complex clamping operations with a fluid stream system that can be easily controlled through fluid pressure regulation. The fluid nozzle delivers consistent contact pressure along the welding contour without requiring complex mechanical actuation, making the operation simpler and more easily adjustable for different welding requirements.
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 allows for reliable and high-quality welding of thermoplastic workpieces with three-dimensional contours without the need for complex clamping tools, ensuring consistent contact pressure and energy transfer, while maintaining flexibility and preventing material deformation, thus enhancing the accuracy and quality of the welded connection.
Implementation Method 1
a laser beam 4, which plasticizes the workpieces 8, 9 at their contact surfaces
Implementation Method 2
the workpiece further away being absorbent for the laser beam of the laser source
Implementation Method 3
which applies at least one fluid stream directly to the workpieces 8, 9, which presses the workpieces together
Data Source
Figure 1~2
Figure 3
AI summary
A laser welding assembly joins thermoplastic components (8,9) and has a socket (13) for the location of workpieces (8, 9). The laser has a socket head (1) for the insertion of the laser emitter (4). The socket head has power wires for the laser emitter and a clamp that presses the components together at their interface during the welding process. The work pieces are located within a flow of cooling air or water.