Laser Welding Head Height Control for Focal Shift Stability
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Solution Overview
Problem
Laser welding quality deteriorates due to shifts in the focal point caused by thermal lens effects and environmental changes, leading to unstable welds, insufficient penetration depth, and potential weld spatter, requiring additional working hours for correction.
Innovation Solution
A laser welding device and method that includes a sensor to detect the intensity of plume light emitted during welding, allowing the controller to adjust the welding head's height in real-time to maintain the focal point's position, thereby stabilizing the energy density distribution of the laser light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser welding is performed without real-time focal point monitoring, then the welding process is simple and fast, but the welding quality deteriorates due to focal point shifts
Solution Approach 1:
The patent implements a feedback control system where a sensor detects plume light intensity during laser welding, the controller compares this with reference values, and automatically adjusts the welding head height to maintain optimal focal point position. This closed-loop feedback mechanism ensures welding quality without manual intervention while managing system complexity through automated control.
Solution Approach 2:
The patent replaces manual mechanical adjustment of the welding head with an automated control system that uses optical sensing (plume light detection) and automated height adjustment. This substitution eliminates the need for operator intervention and maintains consistent welding quality through automated focal point management.
2Reliability
If real-time focal point adjustment is implemented, then welding quality is maintained, but the system complexity increases
Solution Approach 1:
The controller continuously monitors plume light intensity and adjusts the welding head height in real-time to maintain the focal point at the optimal position. This feedback mechanism ensures welding stability and reliability by automatically compensating for focal point shifts without requiring complex manual intervention systems.
Solution Approach 2:
The system performs self-adjustment of the welding head height based on plume light detection, eliminating the need for external operator intervention. The automated control system manages its own focal point optimization, improving reliability while keeping the control mechanism relatively simple.
3Manufacturing precision
If manual correction of focal point shifts is performed, then welding quality can be restored, but additional working time is required
Solution Approach 1:
The patent maintains continuous optimal welding conditions through real-time focal point monitoring and adjustment. The welding process proceeds without interruption or停顿 for manual correction, as the automated system continuously maintains the focal point at the optimal position, ensuring both quality and productivity.
Solution Approach 2:
The feedback control system continuously monitors and adjusts the welding head height during the entire welding process, preventing quality deterioration rather than requiring post-hoc correction. This eliminates the need for additional working time for manual intervention while maintaining welding quality throughout the process.
4Ease of operation
If the welding head height is fixed, then the system is simple to operate, but the focal point shifts during welding due to thermal effects
Solution Approach 1:
The patent transitions from a static fixed welding head height to a dynamic adjustment system that automatically modifies the welding head height in real-time based on plume light detection. This dynamic system maintains focal point stability despite thermal effects during welding, while the automation keeps the system easy to operate without requiring manual adjustment skills.
Solution Approach 2:
The welding head height adjustment is performed automatically by the control system based on plume light feedback, eliminating the need for operator intervention. This self-adjusting mechanism maintains focal point stability while keeping the operation simple, as the system manages its own optimization without user input.
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 effectively suppresses the deterioration in laser welding quality by maintaining the focal point's position, preventing defects like unstable welds and spatter, without increasing working hours for correction.
Implementation Method 1
a sensor that detects, during the laser welding, an intensity of plume light that is based on the laser welding, the plume light being emitted from a welded position
Implementation Method 2
a welding head that is connected to an outgoing end of the fiber and that performs laser welding while irradiating workpiece with the laser light by guiding the laser light from the laser oscillator to the workpiece via the fiber
Implementation Method 3
get a grasp of the amount by which the focal point has shifted during laser welding
Data Source
AI summary
A laser welding device includes: a laser oscillator with which an incoming end of a fiber is connected; a welding head that is connected to an outgoing end of the fiber and that performs laser welding while irradiating a workpiece with laser light by guiding the laser light from the laser oscillator to the workpiece via the fiber; a sensor that detects, during the laser welding, an intensity of plume light that is based on the laser welding at a welded position at which the workpiece is irradiated with the laser light; and a controller that controls a height of the welding head based on a detection output from the sensor, the height being a height in a direction parallel with a direction that the laser light is emitted.