Laser Welding Device with Variable Groove Width Control
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Solution Overview
Problem
Existing laser welding techniques face challenges in achieving consistent welding quality due to variations in the relative position of joining subject members and individual differences, which affect the gap size between the casing and lid of a battery, and limitations in adjusting the intensity distribution of the laser beam.
Innovation Solution
A laser welding device and method that utilize a groove portion with variable width between the casing and lid, where the groove width is detected and adjusted using a detection unit and adjustment force, and the intensity distribution of the laser beam is controlled to optimize welding, using either a top-hat or Gaussian distribution to stabilize the process and prevent sputtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the groove width is fixed by standard tolerances, then the manufacturing process is simple, but the welding quality varies due to relative position differences and individual variations
Solution Approach 1:
The groove width is made dynamically adjustable through inclined surfaces that allow sliding between the casing and lid. The detection unit measures the actual groove width, and the adjustment force application unit modifies the groove width in real-time based on detected values, enabling adaptive compensation for position variations and individual differences during welding.
Solution Approach 2:
A detection unit is implemented to measure the groove width between the casing and lid. The control unit receives this detection signal and adjusts the adjustment force application unit accordingly, creating a closed-loop feedback system that maintains optimal groove width for consistent welding quality despite variations in relative positioning.
2Manufacturing precision
If the laser beam intensity distribution is fixed by the laser oscillator, then the device complexity is low, but the welding process cannot be optimized for different groove widths
Solution Approach 1:
The intensity distribution of the laser beam is made variable by introducing an intensity distribution control unit that can modify the beam profile according to the detected groove width. This allows optimization of welding parameters for different groove conditions without changing the fundamental laser oscillator, achieving better welding control through parameter adjustment.
3Ease of manufacture
If the groove width varies due to tolerances, then ease of manufacture is high, but the molten material flow and welding stability are affected
Solution Approach 1:
The system dynamically adjusts the groove width using inclined surfaces and sliding mechanisms based on real-time detection, maintaining optimal conditions for molten material flow and welding stability despite initial manufacturing tolerances and assembly variations.
Solution Approach 2:
The detection unit continuously monitors groove width, and the control unit adjusts the adjustment force application unit to compensate for variations, ensuring stable welding conditions and consistent molten material flow throughout the welding process.
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
The solution allows for more accurate and stable welding by reducing the influence of relative position and individual differences, ensuring proper molten material flow and preventing thermal deformation, thus enhancing the quality and reliability of the welding process.
Implementation Method 1
a laser beam emitting unit that emits a laser beam to a joining subject portion including an inner side surface of the casing that defines the open portion and a peripheral surface of the lid that faces the inner side surface of the casing
Implementation Method 2
The inner side surface of the casing and the peripheral surface of the lid include inclined surfaces that are slidable on each other and function as a sliding portion
Implementation Method 3
an adjustment force application unit that applies force for adjusting the groove width of the groove portion with the sliding portion
Data Source
AI summary
A laser welding device that laser-welds a lid to an open portion of a casing emits a laser beam to a joining subject portion including an inner side surface of the casing that defines the open portion and a peripheral surface of the lid that faces the inner side surface of the casing. The inner side surface of the casing and the peripheral surface of the lid are arranged to form a groove in between, and include inclined surfaces that function as a sliding portion. The groove portion has a groove width that is variable by sliding the sliding portion. A detection unit detects the groove width of the groove portion. An adjustment force application unit applies force for adjusting the groove width to the casing. A control unit controls the force applied by the adjustment force application unit in accordance with the groove width detected by the detection unit.