Laser Welding Apparatus for Wire Harness Butted Interfaces
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Solution Overview
Problem
The high manufacturing cost of wire harnesses due to the expensive resin used for sealing crimp terminals and the time-consuming resin molding process, as well as the challenge of achieving high-quality laser welding of butted interfaces in wire harnesses.
Innovation Solution
A laser welding apparatus equipped with an X- and Y-axis scanner, a measuring device, and a scanner control device that accurately measures the dimensions of the butted interface and controls the movement of the laser light to ensure high-quality welding, allowing for precise scanning and focusing of the laser along the interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin sealing is used for crimp terminals, then connection reliability is improved, but manufacturing cost increases and production time increases
Solution Approach 1:
The invention extracts and eliminates the resin sealing process from the wire harness manufacturing line. By replacing it with laser welding of the butted interface, the patent removes the costly and time-consuming resin application and curing steps while maintaining protective function through the welded closed structure of the crimp terminal.
Solution Approach 2:
The invention replaces the chemical/thermal resin molding process with a mechanical laser welding process. The laser welding apparatus uses focused laser energy to join the butted interface of the crimp terminal, substituting the entire resin-based sealing system with a direct welding mechanism that achieves both structural integrity and sealing.
2Productivity
If laser welding is used for butted interface, then manufacturing cost is reduced, but welding quality becomes difficult to control
Solution Approach 1:
The invention performs preliminary measurement of the butted interface dimensions before laser welding. The measurement unit scans and captures the actual geometry and gap dimensions of the workpiece, allowing the system to pre-calculate and store scanning parameters that will ensure optimal welding quality for that specific workpiece configuration.
Solution Approach 2:
The invention makes the laser scanning parameters dynamic rather than fixed. Based on the measured butted interface dimensions, the system automatically adjusts scanning speed, laser power, and focal position in real-time. This dynamic adaptation ensures consistent welding quality across workpieces with varying tolerances and geometries.
Solution Approach 3:
The invention implements a feedback loop where measurement data from the butted interface is fed back to the laser welding control system. The measurement results directly influence the welding parameters, creating a closed-loop control system that automatically compensates for variations in workpiece geometry and maintains high welding quality.
3Area of stationary object
If laser focus is moved along butted interface, then welding coverage is improved, but measurement precision is required
Solution Approach 1:
The invention uses a single measurement device that performs multiple functions: it measures the butted interface geometry, determines the optimal laser scanning path, calculates welding parameters, and validates the final weld quality. This multi-functional approach consolidates what would otherwise require separate measurement and control systems.
Solution Approach 2:
The invention changes the measurement parameters based on the specific workpiece being welded. The system adapts measurement resolution, scanning density, and data processing algorithms according to the size, material, and geometric complexity of each butted interface, optimizing both measurement accuracy and processing efficiency for each case.
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 enables high-quality laser welding of butted interfaces by accurately measuring and controlling the laser light movement, reducing defects and variations, and potentially stopping the press machine or issuing alerts when gaps exceed predetermined limits, thus improving the manufacturing efficiency and reducing costs.
Implementation Method 1
a laser light source that emits laser light; an X- and Y-axis scanner that scans the laser light in an X-axis direction and a Y-axis direction which are orthogonal to each other
Implementation Method 2
a measuring device that measures a dimension of the butted interface
Data Source
AI summary
A laser welding apparatus that welds a butted interface of a workpiece by laser light irradiation while successively feeding the workpiece having the butted interface to a welding position includes an X- and Y-axis scanner that scans laser light outputted from a laser light source in an X-axis direction and a Y-axis direction which are orthogonal to each other, a measuring device that measures a dimension along the butted interface, and a scanner control device that controls driving of the X- and Y-axis scanner so as to weld the butted interface by laser light irradiation.