Laser Welding Media Supply Layout for Clear Joint Tracking
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Solution Overview
Problem
Existing laser welding methods face challenges in precision and accessibility due to the opposing arrangement of filler material and process gas nozzles, which restrict access and obstruct sensor views of the welding joint, and the rigid design of combination nozzles limits process dynamics and contour freedom.
Innovation Solution
A laser welding device with an optical monitoring system to detect the welding joint course and a supply device that provides filler material and process gas from a direction following the laser beam, allowing for precise welding and flexible media supply based on the welding task, with modular components for independent gas and filler material delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If filler material and process gas are supplied by separate nozzles mounted opposite one another, then both media can be supplied simultaneously, but access to the component is restricted and the welding process zone is difficult or impossible to see for sensors
Solution Approach 1:
The patent combines the filler material nozzle and process gas nozzle into a single integrated supply device with a common housing. This merging allows both media to be supplied through one compact unit, improving access to the welding zone while maintaining the capability to supply both filler material and shielding gas simultaneously.
Solution Approach 2:
Within the unified supply device, the patent maintains separate internal channels and outlets for filler material and process gas. This segmentation allows independent control and supply of each medium while benefiting from the compact integrated structure, resolving the contradiction between simultaneous media supply and component accessibility.
2Ease of operation
If a combination nozzle is used for leading supply of filler material and process gas, then access is improved, but the rigid design limits dynamics and contour freedom for many welding tasks
Solution Approach 1:
The supply device incorporates adjustable components that allow the nozzle orientation and media flow characteristics to be dynamically adapted during welding operations. This enables the system to maintain both improved access and the flexibility needed for different welding contours and tasks.
Solution Approach 2:
The integrated supply device is designed to perform multiple functions - supplying filler material, providing shielding gas, and accommodating various welding configurations. This multi-functionality allows a single device to adapt to different welding tasks while maintaining the benefits of a unified structure.
3Quantity of substance
If separate nozzles are used for filler material and process gas, then media supply is effective, but the opposing arrangement creates unnecessary negative influence on dynamics when only one medium is required
Solution Approach 1:
By merging the filler material and process gas supply into a single integrated device, the patent reduces the number of separate components and mounting requirements. This consolidation maintains effective media supply while simplifying the overall nozzle configuration and reducing device complexity.
Solution Approach 2:
The patent extracts the essential media supply functions into a unified device structure, eliminating the need for separate opposing nozzles. This extraction simplifies the system by removing redundant components while preserving the core functionality of supplying both filler material and shielding gas.
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 precision and quality by enabling unobstructed monitoring and adaptable media supply, improving dynamics and accessibility during the welding process.
Implementation Method 1
an optical monitoring device configured to be aligned with an observation region around the welding joint in order to detect a course of the welding joint
Implementation Method 2
metallic workpieces are melted along a welding joint by means of a laser beam
Implementation Method 3
the laser beam...melting the joining partners
Data Source
AI summary
A laser welding device welds two joining partners along a welding joint. The laser welding device includes: an optical monitoring device configured to be aligned with an observation region around the welding joint in order to detect a course of the welding joint; a laser welding head configured to direct a laser machining beam onto at least one of the joining partners by means of a welding optics on the basis of the detected course of the welding joint along the welding joint; and a supply device configured to provide a filler material and/or a process gas and which is arranged on the laser welding head such that the filler material and/or the process gas can be supplied to a welding process from a supply direction following the machining laser beam.