Laser Welding Layout With Multi-Nozzle Shielding for Coil Segments
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Solution Overview
Problem
Existing laser welding technologies face challenges in preventing oxidation and metal vapor interference during rapid welding of multiple coil segments in rotating electrical machines, particularly when using galvano lasers with wide irradiation ranges.
Innovation Solution
A laser welding apparatus and method that fixes the workpiece to arrange welding parts linearly, uses a laser head that changes emission angles, and simultaneously blows inert gas onto all parts, with dedicated nozzles on both sides to prevent oxidation and a carrier gas flow to manage metal vapor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a galvano laser is used to perform rapid welding of multiple coil segments, then welding speed and productivity are improved, but it becomes difficult to cover the entire irradiation range with an outer cylinder and blow shield gas from around the laser light
Solution Approach 1:
The shield gas supply system is divided into multiple nozzles positioned at different locations along the laser irradiation path. Each nozzle supplies shield gas to a specific segment of the welding area, collectively covering the entire irradiation range of the galvano laser while maintaining high welding speed
Solution Approach 2:
Multiple nozzles are introduced as intermediary components between the laser light and the welding area. These nozzles deliver shield gas to different portions of the welding zone, enabling comprehensive oxidation prevention across the wide irradiation range without requiring a single large outer cylinder
2Reliability
If an outer cylinder is used to cover the laser emission port and blow shield gas, then oxidation of the welding part is prevented, but the device complexity increases and it becomes difficult to apply to galvano lasers with wide irradiation ranges
Solution Approach 1:
Instead of using a single complex outer cylinder structure, the shield gas supply is segmented into multiple simpler nozzles positioned at different locations. This segmentation reduces the complexity of each individual component while collectively achieving the same oxidation prevention function across the entire welding area
Solution Approach 2:
The shield gas supply approach transitions from a single-dimensional outer cylinder enclosing the laser emission port to a multi-dimensional arrangement of nozzles positioned along the laser irradiation path. This dimensional change enables coverage of the wide irradiation range with simpler components
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
Enables rapid and reliable welding of multiple parts by preventing oxidation and metal vapor interference, reducing manufacturing time and improving welding reliability.
Implementation Method 1
a laser irradiation device configured to melt welding required parts of the welding target workpiece by laser light emitted from a laser head
Implementation Method 2
melt welding required parts of the welding target workpiece by laser light emitted from a laser head
Implementation Method 3
an inert-gas nozzle configured to simultaneously blow inert gas onto all of the plurality of linearly consecutive welding required parts
Data Source
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AI summary
A laser welding apparatus (20) includes: a fixing tool (22) configured to fix a welding target workpiece (11); and a laser irradiation device (30) configured to melt welding required parts (10) of the welding target workpiece (11) by laser light emitted from a laser head (31), the fixing tool (22) being configured to be capable of fixing the welding target workpiece (11) such that the welding required parts (10) are arranged linearly in plural numbers in a consecutive manner at predetermined intervals, and the laser irradiation device (30) being configured to successively melt the plurality of welding required parts (10) by changing an emission angle of the laser light emitted from the laser head (31), wherein the laser welding apparatus (20) further includes an inert-gas nozzle (41) configured to simultaneously blow inert gas onto all of the plurality of linearly consecutive welding required parts (10).