Laser Welding Paths for Wire Ends With Gap-Tolerant Joining
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Solution Overview
Problem
Existing laser welding methods for wire-shaped members face challenges in preventing laser beam irradiation into gaps between end portions, leading to potential damage of coatings or adjacent members, and require complex configurations or measurement devices to manage dimensional fluctuations.
Innovation Solution
A laser welding method that alternately irradiates a laser beam along loop-shaped and linear movement paths between the end portions of adjacent wire-shaped members, ensuring the laser beam is not directed into gaps by predetermining movement paths based on the cross-sectional shape and dimensions of the members, simplifying the process and eliminating the need for complex control programs or measurement devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is used to closely adhere the end portions of wire-shaped members to each other, then the gap between end portions is reduced, but the complexity of the device increases and dimensional fluctuations of end portions make it difficult to prevent gaps
Solution Approach 1:
The patent extracts and eliminates the jig from the welding system by adopting a gap-tolerant laser welding method. Instead of using mechanical fixtures to hold wire ends together, the system directly welds wires with gaps using controlled laser irradiation parameters that accommodate dimensional fluctuations without requiring additional positioning devices.
Solution Approach 2:
The patent changes the laser welding parameters (irradiation power, speed, pattern) to enable welding across gaps. By adjusting these parameters, the system can weld wire-shaped members with varying gap dimensions without requiring precise mechanical positioning, thus reducing device complexity while maintaining weld quality.
2Object-affected harmful factors
If laser beams are individually irradiated respectively on the end portions of two wire-shaped members, then the laser beam is prevented from being irradiated into the gap, but the configuration and control program of the laser welding device becomes complex
Solution Approach 1:
The patent merges the irradiation control of multiple laser beams into a unified control system. Instead of independently controlling separate laser beams for each wire end, the system uses a single laser beam with coordinated movement that irradiates both wire ends in sequence, simplifying the control program while preventing laser beam leakage into the gap.
Solution Approach 2:
The patent employs periodic action by alternately irradiating the laser beam on different wire-shaped members in a cyclic manner. The laser beam irradiates the first wire end, then moves to and irradiates the second wire end, repeating this cycle. This periodic irradiation pattern prevents continuous laser exposure that could leak into the gap while maintaining simple control logic.
3Object-affected harmful factors
If the irradiation of the laser beam is stopped when moving from one end portion to the other, then the laser beam is prevented from being irradiated into the gap, but measurement devices and processes are required to measure gap dimensions
Solution Approach 1:
The patent implements self-service by enabling the laser welding system to automatically adapt to gap variations without external measurement devices. The control system uses pre-stored movement paths and irradiation parameters that inherently accommodate dimensional fluctuations, allowing the system to self-adjust and prevent laser leakage without requiring separate measurement and calculation processes.
Solution Approach 2:
The patent applies preliminary action by pre-storing optimal laser beam movement paths and irradiation parameters before welding begins. These pre-programmed parameters are designed to accommodate expected dimensional fluctuations and gap variations, allowing the system to prevent laser leakage into the gap through advance preparation rather than real-time measurement and adjustment.
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
Effectively prevents laser beam irradiation into gaps between wire-shaped members, reducing the risk of damage while maintaining efficient heating and weld quality, even with dimensional fluctuations, and simplifies the control program and device configuration.
Implementation Method 1
a laser beam is irradiated on an end portion of one wire-shaped member and an end portion of the other wire-shaped member adjacent to the one wire-shaped member to weld the end portions of the two wire-shaped members to each other
Implementation Method 2
the laser beams can be prevented from being irradiated into the gap between the end portions of the wire-shaped members
Implementation Method 3
laser beams are individually irradiated respectively on the end portions of the two wire-shaped members
Data Source
AI summary
According to one embodiment, a laser welding method includes a process of irradiating the laser beam along a first movement path, a second movement path, a third movement path, and a fourth movement path at an end portion of a first wire-shaped member and a second wire-shaped member, the first movement path being loop-shaped; the second movement path being linear; the third movement path being loop-shaped; and the fourth movement path being linear.