Laser Welding Spherical Elements Optoelectronic Detection
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Solution Overview
Problem
Existing methods for connecting vehicle components using spherical elements are limited in utilizing their properties for precise positioning and welding, leading to inefficiencies in seam weld production.
Innovation Solution
A method utilizing an optoelectronic detection apparatus to detect the position of spherical elements and control a contactless electronically controlled laser welding device to produce a seam weld relative to the element's position, allowing for precise and efficient component connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional contact-based welding methods are used, then welding can be performed on spherical elements, but positioning precision and manufacturing efficiency are limited
Solution Approach 1:
The patent replaces traditional mechanical contact-based welding methods with a contactless laser welding system. The laser welding device uses optical energy to melt and join components without physical contact, enabling precise positioning of weld seams relative to spherical elements while significantly improving manufacturing efficiency and productivity.
Solution Approach 2:
The patent introduces an optoelectronic detection apparatus as an intermediary to detect the position of spherical elements and generate position data. This detection system serves as a mediator between the spherical element positioning and the laser welding process, enabling precise control of weld seam placement based on detected spherical element positions.
2Adaptability or versatility
If spherical elements are used for component connection, then versatile application options are opened, but precise positioning for weld seam production becomes difficult
Solution Approach 1:
The optoelectronic detection apparatus acts as an intermediary that specifically addresses the measurement challenge of spherical elements. It detects the position of spherical elements with high precision and generates corresponding position data, which is then used to control the laser welding device for accurate weld seam placement.
Solution Approach 2:
The system implements a feedback mechanism where the optoelectronic detection apparatus continuously monitors the position of spherical elements, generates position data, and this information is fed back to control the laser welding device. This closed-loop feedback ensures precise positioning and placement of weld seams relative to the spherical elements.
3Productivity
If contactless laser welding is used, then manufacturing efficiency improves, but precise control relative to spherical elements becomes challenging
Solution Approach 1:
The system uses real-time position data from the optoelectronic detection apparatus as feedback to control the laser welding device. This feedback mechanism ensures that the contactless laser welding process maintains high precision in weld seam placement relative to spherical elements while preserving the productivity benefits of contactless operation.
Solution Approach 2:
The patent replaces mechanical contact-based positioning and welding with an optically-controlled system. The laser welding device is electronically controlled based on position data, substituting mechanical positioning methods with optical detection and electronic control, thereby achieving both high efficiency and high precision.
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 secure and permanent connection of components with precise weld seam placement, leveraging the reflective properties of spherical elements for accurate positioning and welding, enhancing manufacturing efficiency.
Implementation Method 1
When a light ray is incident on the surface of a spherical element, 'angle of incidence equals angle of reflection' applies very generally. A light ray which is incident perpendicular to a surface point of the spherical or sphere-like element is reflected 'onto itself', which is referred to as 'total reflection' below.
Implementation Method 2
the weld seam is produced in a contactless manner by an electronically controlled laser welding device arranged at a distance from the first component and the at least one spherical or sphere-like element
Data Source
AI summary
A method is provided for producing a weld seam on or at a first component, or in the region of a first component, from which at least one spherical or sphere-like element projects. The position of the at least one spherical or sphere-like element is detected using an optoelectronic detection device and corresponding position data are generated. The weld seam is produced contact free using an electronically-controlled laser welding device that is arranged at a distance from the first component and said at least one spherical or sphere-like element. The laser welding device is controlled on the basis of, or using, the position data of the spherical or sphere-like element.