Laser Welding System Vibration Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser welding systems face challenges in precisely correcting for laser beam divergence due to vibrations in the robot arm, leading to reduced precision in welding operations.
Innovation Solution
A laser welding system that incorporates an acceleration acquisition section, such as an acceleration sensor, electric current sensor, or imaging device, to detect and correct for vibrations by adjusting the control commands for the galvano motor, thereby counterbalancing the acceleration component and suppressing divergence in the laser beam irradiation position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vibration control function is used to correct laser beam irradiation position divergence, then welding precision is improved, but load on servomotor and reduction gears increases greatly
Solution Approach 1:
The patent replaces the mechanical vibration control approach (which requires large torque from servomotors and reduction gears) with an optical compensation approach. By detecting the actual laser beam irradiation position and calculating the required galvanoscanner mirror angle adjustments, the system compensates for vibrations through optical path correction rather than mechanical counter-vibration, thereby avoiding increased mechanical load while maintaining welding precision.
2Device complexity
If only slope detection with gyrosensor is used to correct galvanoscanner operation, then device complexity is reduced, but lateral divergence correction capability is lost
Solution Approach 1:
The patent extends the detection capability from one-dimensional slope measurement (gyrosensor only) to two-dimensional position detection by adding a laser sensor that measures both lateral and angular deviations. This dimensional expansion enables comprehensive correction of all vibration-induced beam position divergences, including lateral divergence that was previously undetectable, thereby improving correction precision without excessive complexity increase.
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 approach enables high-precision correction of laser beam divergence, enhancing the precision of laser welding without increasing the load on the robot's motors or reduction gears.
Implementation Method 1
an acceleration acquisition section that acquires acceleration of vibration occurring at the leading end of the arm due to operation of the robot
Implementation Method 2
at least one mirror which is configured to be rotatable around a rotation axis, and reflects the laser beam
Data Source
AI summary
To provide a laser welding system that can correct divergence of a laser beam irradiation position with higher precision, and is capable of higher precision laser welding. A remote laser welding system (1) includes: a multi-axis robot (3); a laser head (5) provided to a leading end of an arm (31) of the multi-axis robot (3); a control unit (7) that controls operations of the multi-axis (3) and the laser head (5); and a laser light source (53), in which the laser head (5) includes: two galvano mirrors (51, 52) configured to be rotatable about rotational axes (X1, X2), respectively, and reflect a laser beam; and galvano motors (54) that rotationally drive the galvano mirrors (51, 52), and in which the control unit (7) includes an acceleration sensor (73) that acquires the acceleration of the vibration; and a command correction section (74) that corrects a control command to the galvano motors (54) which rotationally drive the galvano mirrors (51, 52), based on the acceleration of the vibration acquired by the acceleration sensor (73), so as to suppress divergence of the laser beam irradiation position due to vibration.