Laser Welding Mirror Assembly for Stable End-Face Alignment
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Solution Overview
Problem
Conventional laser welding machines experience instability and inaccuracy due to the connecting rod assembly affecting the laser gun during displacement, leading to offset welding.
Innovation Solution
A laser welding device with a base, positioning assembly, reflection assembly, drive assembly, and linkage rotation assembly that allows the laser device and reflection assembly to rotate about a central axis, maintaining the workpieces stationary, using simple gear engagement to eliminate complex linkage structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connecting rod assembly is used to connect the laser welding machine and achieve three-dimensional position and angle changes, then the positioning flexibility is improved, but the stability of the laser gun deteriorates due to displacement effects causing offset welding
Solution Approach 1:
The system is divided into independent functional modules: the laser gun assembly remains fixed on the base while the workpiece is positioned and rotated separately. This segmentation eliminates the coupling between laser positioning and workpiece positioning, allowing the laser to maintain stable alignment while the workpiece moves into the correct position for welding.
Solution Approach 2:
Instead of moving the laser gun to track the workpiece (conventional approach), the invention inverts the approach by keeping the laser stationary and moving/rotating the workpiece into the laser beam. This inversion eliminates the instability caused by laser gun displacement while achieving the same positioning flexibility.
2Adaptability or versatility
If a complex linkage structure is used to enable laser gun movement and rotation, then the positioning capability is improved, but the device complexity increases leading to higher manufacturing costs
Solution Approach 1:
The complex linkage mechanism traditionally required to move and position the laser gun is completely extracted and removed from the system. Instead, a simple rotational mechanism is used to rotate the workpiece, eliminating the need for complex linkages while maintaining full positioning capability.
Solution Approach 2:
The complex mechanical linkage system is replaced with a simpler rotational positioning mechanism. The workpiece rotates into position under the stationary laser, substituting a simple rotational motion for a complex multi-degree-of-freedom linkage system, thereby reducing device complexity and manufacturing costs.
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
Improves welding accuracy and reduces manufacturing costs by ensuring steady laser rotation and eliminating the need for complex linkage structures.
Implementation Method 1
a reflection assembly (4) attached to the fixed clamp (21) and includes a reflection mirror (41) corresponding to the laser device (3)
Data Source
AI summary
A laser welding device includes a base having two support members to fix a first workpiece and a second workpiece. A positioning assembly positioned above the base includes a fixed clamp and two connecting pieces which are respectively located on both sides of the fixed clamp. A laser device and a reflection assembly are respectively attached to the fixed clamp. The fixed clamp is connected to a support assembly. The reflection assembly includes a reflection mirror corresponding to the laser device. A drive assembly is attached to the support assembly of the laser device. A linkage rotation assembly is connected between the drive assembly and the connecting pieces of the positioning assembly. The positioning assembly gathers two respective end faces of the first and second workpieces to proceed end-to-end welding operation by the laser device, the reflection assembly, and the linkage rotation assembly to the two respective end faces.