Laser Beam and Filler Wire Alignment Using Optical Feedback
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Solution Overview
Problem
In laser joining processes, maintaining consistent alignment between the filler wire and the laser beam is crucial for joint quality, but existing methods lack efficiency, accuracy, and flexibility in achieving and maintaining this alignment across various operations.
Innovation Solution
A system and method that utilize a controller, sensor system, and actuator to align a laser beam with a filler wire by measuring light intensity and computing a feature parameter, adjusting the alignment as needed to ensure the wire is properly positioned within process specifications, using a pilot laser beam and a filter to filter background light and ensure accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional alignment methods are used, then the system is simpler, but alignment precision and repeatability are insufficient
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated optical sensing system. A sensor detects the position of the filler wire relative to the laser beam, and a controller automatically adjusts the wire feed system to achieve precise alignment, eliminating the need for complex manual positioning while improving measurement precision.
Solution Approach 2:
The alignment system performs self-adjustment through automatic detection and correction. The sensor continuously monitors wire position, and the controller automatically modifies feed parameters to maintain optimal alignment, enabling the system to self-correct without external intervention and improving repeatability.
2Manufacturing precision
If manual alignment adjustment is used, then the system is easier to operate, but alignment consistency and joint quality are compromised
Solution Approach 1:
The patent implements a closed-loop feedback system where the sensor continuously detects wire position relative to the laser beam, and the controller automatically adjusts the wire feed system based on this feedback. This ensures consistent alignment and high joint quality while reducing the need for manual intervention and simplifying operation.
3Adaptability or versatility
If fixed alignment tooling is used, then setup is simpler, but adaptability to different joining operations is reduced
Solution Approach 1:
The patent employs dynamic alignment adjustment capabilities where the wire feed system can be automatically repositioned and realigned for different joining operations. The sensor-based detection and controller-driven adjustment enable the system to adapt to various wire positions, beam parameters, and joint configurations, providing flexibility without requiring multiple fixed tooling setups.
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 ensures precise and repeatable alignment of the wire relative to the laser beam, improving the quality of the joint produced and allowing for flexibility across different joining operations.
Implementation Method 1
The sensor system measures light intensity of the beam
Implementation Method 2
a filter to filter background light and ensure accurate alignment
Data Source
AI summary
Systems and methods determine alignment between a wire and a laser beam in laser joining. A system for checking alignment of a wire relative to a beam of a laser includes a controller configured to align, by tooling, the beam with a sensor system. A laser generates the beam across the wire, with the beam directed to the sensor system. The sensor system measures light intensity of the beam. A processor computes a feature parameter representative of an alignment between the wire and the beam. The processor determines whether the feature parameter is within the process specifications.