Laser Welding Device for Roll Formed Beams
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Solution Overview
Problem
Conventional roll forming systems require additional welding processes for vehicle bumper beams, such as spot welding or cold metal transfer welding, which are time-consuming and may compromise the quality of the weld.
Innovation Solution
A laser welding device is integrated into the roll forming system to real-time weld shaped beams by controlling the output and moving speed of a laser beam focus based on forming speed, forming a predetermined zigzag welding pattern without the need for additional welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional welding processes (spot welding or cold metal transfer welding) are used for vehicle bumper beams, then welding can be performed, but the production time increases and welding quality may be compromised
Solution Approach 1:
The patent combines the roll forming process and welding process into a single integrated system. The laser welding device is positioned within the roll forming line to perform welding operations on shaped beams during the forming process, eliminating the need for separate post-forming welding operations. This merging of processes reduces production time while maintaining welding quality through real-time welding control.
Solution Approach 2:
The patent replaces traditional mechanical welding methods (spot welding or cold metal transfer welding) with laser welding technology. The laser welding device uses optical energy to melt and join metal components, providing superior welding quality with reduced production time compared to conventional mechanical welding processes.
2Productivity
If laser welding is performed on shaped beams during roll forming, then additional welding processes are eliminated, but real-time control of laser output and focus speed is required
Solution Approach 1:
The patent implements a feedback control system that monitors the roll forming speed and automatically adjusts the laser output power and focus moving speed accordingly. The controller receives signals from the roll forming line and dynamically controls the laser welding parameters to maintain optimal welding conditions, simplifying the overall control complexity through automated feedback mechanisms.
Solution Approach 2:
The patent employs dynamic control of the laser focus position and output power that adapts to varying roll forming speeds. The system automatically adjusts welding parameters in real-time based on the forming speed of the shaped beam, enabling flexible production while maintaining welding quality without requiring complex manual intervention.
3Reliability
If the focus of the laser beam moves at constant speed, then the laser welding device is simple to operate, but welding quality varies when forming speed changes
Solution Approach 1:
The patent dynamically changes the laser focus moving speed and output power parameters based on the roll forming speed. The controller adjusts these parameters in real-time to maintain consistent welding quality across different production speeds, eliminating the need for manual parameter adjustments while ensuring reliable welding results.
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 real-time laser welding of shaped beams within the roll forming system, improving welding quality by eliminating the need for additional welding processes and ensuring consistent, high-quality welds along a predetermined pattern.
Implementation Method 1
laser welding means mounted above and between the front and rear guide means, reciprocatedly rotating a mirror by controlling a mirror motor so as to irradiate a laser beam to a welding position of the shaped beam, and thereby forming a welding bead having a predetermined welding pattern
Implementation Method 2
controlling an output and a moving speed of a focus of a laser beam according to a forming speed
Data Source
AI summary
A roll forming system which roll-forms a shaped beam by a roll forming unit including a plurality of roll formers is disclosed. A laser welding device for the roll forming system may include: front and rear guide means disposed apart from each other at the rear of the roll forming unit, and guiding movement of the shaped beam; laser welding means mounted above and between the front and rear guide means, reciprocatedly rotating a mirror by controlling a mirror motor so as to irradiate a laser beam to a welding position of the shaped beam, and thereby forming a welding bead having a predetermined welding pattern; forming speed detecting means detecting a forming speed of the shaped beam and transmitting a signal corresponding thereto to a controller; a camera disposed at the rear of the laser welding means, photographing a welding portion of the shaped beam, and transmitting an image signal corresponding thereto to the controller.