Laser Welding Line Calibration for Misalignment and Quality Inspection
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Solution Overview
Problem
Conventional welding methods struggle to maintain stable welding quality, particularly in applications like battery module assembly, where precise alignment is crucial to avoid deviations in the welding work line.
Innovation Solution
A welding device equipped with a scanner, welding laser, galvo module, scan laser, and a processor that controls these components to scan the boundaries of materials, calibrate the welding work line, and form a keyhole for precise welding, while also inspecting welding quality in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding method is used, then welding process is simple, but welding quality is not stable
Solution Approach 1:
The system performs preliminary scanning and calibration of the welding work line before actual welding. The processor scans boundaries of materials to obtain coordinate information and calibrates the welding work line in advance, ensuring accurate positioning and stable welding quality before the welding process begins.
Solution Approach 2:
The system uses real-time feedback through scanning and calibration processes. The processor continuously monitors the welding work line position and makes adjustments based on scanned coordinate information, creating a closed-loop control system that maintains welding quality stability.
2Manufacturing precision
If welding object is misaligned, then placement is flexible, but welding work line deviates
Solution Approach 1:
The system performs preliminary scanning and calibration of the welding work line before actual welding. The processor scans boundaries of materials to obtain coordinate information and calibrates the welding work line in advance, ensuring accurate positioning and stable welding quality before the welding process begins.
Solution Approach 2:
The system dynamically adjusts welding work line parameters based on scanned coordinate information. When misalignment is detected, the processor modifies the welding work line coordinates and positioning parameters to compensate for placement errors, maintaining welding accuracy despite variations in material positioning.
3Reliability
If real-time welding inspection is added, then welding quality is improved, but device complexity increases
Solution Approach 1:
The inspection function is merged with the existing scanning system. The same scanner and processor used for welding work line calibration are also utilized for real-time welding quality inspection, combining multiple functions into a single integrated system rather than adding separate inspection equipment.
Solution Approach 2:
The scanning system serves multiple purposes: it scans boundaries for work line calibration, monitors welding process in real-time, and inspects welding quality. This multi-functional approach eliminates the need for separate dedicated inspection devices, reducing overall system complexity while maintaining inspection capabilities.
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 solution significantly improves welding accuracy by calibrating the welding work line even when the welding object is misaligned, and enables real-time inspection of welding quality, reducing defects and enhancing overall welding performance.
Implementation Method 1
a welding laser configured to emit light toward the scanner
Implementation Method 2
control the welding laser and the scanner to form a keyhole
Implementation Method 3
a scanner configured to deflect light
Implementation Method 4
a scan laser configured to emit light toward the galvo module
Data Source
AI summary
A welding device for welding a plurality of materials arranged to be in contact includes a scanner configured to deflect light; a welding laser configured to emit light toward the scanner; a galvo module configured to deflect light toward the scanner; a scan laser configured to emit light toward the galvo module; and a processor configured to control at least one of the scanner and the galvo module to scan boundaries of the plurality of materials.