Laser Welding Alignment With Vision-Guided Focal Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual alignment of elongated elements in welding is inefficient and poses safety risks, with unstable precision affecting welding quality.
Innovation Solution
A welding system incorporating a vision device for precise alignment, a moving mechanism to accurately position elongated elements under the laser beam, and a protective gas injection device to prevent oxidation, with closed-loop feedback control for optimal alignment and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment is used to position elongated elements, then the operator can directly observe and adjust the elements, but the welding efficiency is very low and the alignment precision is unstable
Solution Approach 1:
The patent replaces the manual mechanical alignment system with an automated vision-based alignment system. The vision device captures images of the elongated elements, and a control system automatically calculates and adjusts the positions, eliminating manual observation and adjustment while improving both precision and efficiency.
Solution Approach 2:
The system enables self-alignment through automated vision guidance and control. The elongated elements are automatically positioned based on vision device feedback without requiring operator intervention, allowing the system to service itself in terms of alignment operations.
2Ease of operation
If manual alignment is used, then the operator can adjust the elements, but the operator may be hurt by the laser beam creating security risks
Solution Approach 1:
The patent extracts the operator from the hazardous laser beam environment by implementing automated alignment and positioning systems. The vision device and control system perform all alignment functions remotely, eliminating the need for operator proximity to the laser beam during welding operations.
Solution Approach 2:
The vision device and control system serve as intermediaries between the operator and the welding process. The operator interacts with the system through control interfaces rather than directly manipulating elements near the laser beam, with the automated system mediating all positioning and alignment actions.
3Reliability
If manual alignment is used, then the operator can position the elements, but the welding quality cannot be guaranteed due to unstable precision
Solution Approach 1:
The patent implements a closed-loop feedback system where the vision device continuously monitors the positions of elongated elements, and the control system automatically adjusts positions based on real-time feedback. This ensures consistent alignment precision and reliable welding quality by eliminating manual variation.
Solution Approach 2:
The system performs preliminary alignment and positioning actions automatically before welding begins. The vision device pre-positions the elongated elements with high precision, and the control system verifies alignment before initiating the welding process, ensuring consistent quality from the start.
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
Enhances welding efficiency and accuracy by automating alignment and ensuring precise positioning of elongated elements within the laser beam, while protecting against oxidation, thereby improving overall welding quality and safety.
Implementation Method 1
the operator turns on a laser welding head to weld the aligned ends of the pair of elongated elements together by a laser beam emitted from the laser welding head
Implementation Method 2
the protective gas injection device is adapted to spray a protective gas to a welding area of the first elongated element and the second elongated element, so as to protect the first elongated element and the second elongated element from being oxidized during welding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A welding system configured to weld a first elongated element (10) and a second elongated element (20) together, and comprising: a first moving mechanism (510); a first fixture (410) adapted to fix the first elongated element (10); a second moving mechanism (520); a second fixture (420) adapted to fix the second elongated element (20); and a laser welding head (100) adapted to emit a laser beam (110), wherein the first fixture (410) is mounted on the first moving mechanism (510), and the first moving mechanism (510) is configured to move the first fixture (410), so that the first elongated element (10) fixed on the first fixture (410) is aligned with the second elongated element (20) fixed on the second fixture (420), and wherein the first moving mechanism (510) and the second fixture (420) are mounted on the second moving mechanism (520), and the second moving mechanism (520) is configured to move the first moving mechanism (510) and the second fixture (420), so that an ideal welding center point (C') of the aligned first and second elongated elements (10, 20) is accurately located at a focal point (C) of the laser beam (110) from the laser welding head (100). The ideal welding center point of the aligned first and second elongated elements may be quickly and accurately moved to the focal point of the laser beam emitted from the laser welding head by the second moving mechanism.