Laser Galvanometer Positioning for Battery Post Welding Focus Control
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Solution Overview
Problem
During the welding of battery product posts, an inappropriate distance between the laser galvanometer and the post can lead to poor welding quality, affecting product yield.
Innovation Solution
A welding system comprising a controller, a robot, a laser galvanometer, and a rangefinder, where the rangefinder and laser galvanometer are connected to the robot, allowing for precise positioning adjustments based on ranging values to achieve an optimal distance for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the laser galvanometer and the post is not properly adjusted, then the welding quality deteriorates, but adjusting the position requires additional measurement and control complexity
Solution Approach 1:
The rangefinder performs preliminary measurement of the distance between the laser galvanometer and the post before welding. Based on this measurement, the system calculates the required position adjustment amount in advance, allowing the laser galvanometer to be positioned at the optimal distance for welding, thereby ensuring high welding quality without requiring complex real-time adjustment mechanisms
Solution Approach 2:
The system uses the rangefinder to obtain actual distance information, compares it with the preset optimal distance, calculates the deviation, and feeds back this deviation information to control the position adjustment of the laser galvanometer. This closed-loop feedback mechanism ensures the laser galvanometer maintains the correct distance from the post, guaranteeing welding quality while using a relatively simple adjustment system
2Adaptability or versatility
If the laser galvanometer position is fixed, then the device complexity is reduced, but the adaptability to different welding positions and distances deteriorates
Solution Approach 1:
The system transforms the static fixed position of the laser galvanometer into a dynamic adjustable position. By introducing the rangefinder for real-time distance measurement and the position adjustment mechanism controlled by the controller, the laser galvanometer can dynamically adapt its position to match different welding requirements, enhancing adaptability while keeping the adjustment mechanism relatively simple
Solution Approach 2:
The system changes the positional parameter of the laser galvanometer based on measured distance information. By calculating the deviation between the actual distance and the preset optimal distance, the system adjusts the laser galvanometer's position parameter to ensure it maintains the correct distance from the post, thereby achieving adaptability to different welding scenarios without requiring a complex adjustment mechanism
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 system improves welding quality and increases product yield by accurately determining the position adjustment amount for the laser galvanometer, ensuring a precise distance between the laser and the post.
Implementation Method 1
the robot is configured to drive the rangefinder to perform ranging, along the first direction, of at least two posts in a battery product to be welded, so as to obtain a set of ranging values between the at least two posts and the rangefinder
Implementation Method 2
drive the position-adjusted laser galvanometer to move perpendicularly to the first direction, so as to weld the at least two posts
Data Source
AI summary
A method includes obtaining a set of ranging values between a rangefinder and at least two posts in a battery product, where the set of ranging values is obtained by the rangefinder through ranging of the at least two posts along a first direction parallel to an optical axis of a laser galvanometer after the rangefinder is calibrated based on a first position in the first direction that is a position of a focal point of the laser galvanometer in the first direction, and the rangefinder being at a fixed distance from the laser galvanometer in the first direction; determining a first offset of a welding surface of the battery product relative to the focal point 10 based on the set of ranging values; and determining a first position adjustment amount for the laser galvanometer in the first direction based on the first offset and a first defocus amount.