Laser Brazing Wire Jig for Automatic Position Monitoring
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Solution Overview
Problem
Current laser brazing systems require manual inspection to ensure the correct positioning of the braze wire, which disrupts productivity and can result in defective parts due to the need for additional auxiliary lasers to prevent wire melting during monitoring.
Innovation Solution
A laser brazing system that uses a jig to block and measure the laser beam, allowing for automatic determination of the braze wire's position relative to the radiation path without additional lasers, utilizing a control unit to compare detected light signals and determine if the wire is within a predetermined range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of wire position is performed, then positioning accuracy can be verified, but productivity decreases due to process interruption
Solution Approach 1:
The patent replaces manual mechanical inspection with an optical detection system. A detector measures the position of the braze wire automatically by detecting light signals, eliminating the need for manual intervention while maintaining measurement accuracy. This substitution of mechanical/manual processes with optical/automated systems resolves the contradiction between inspection accuracy and production continuity.
2Extent of automation
If auxiliary laser source is added for monitoring, then wire position can be monitored automatically, but device complexity increases
Solution Approach 1:
The patent makes the primary laser beam serve dual functions: both brazing processing and wire position monitoring. By using the same laser beam for both purposes, the system eliminates the need for separate auxiliary laser sources while achieving automatic monitoring capability. This multi-functionality approach reduces device complexity while maintaining automation.
Solution Approach 2:
The patent introduces a detector as an intermediary device that measures wire position by detecting light signals from the laser beam without requiring additional laser sources. The detector acts as a mediator between the laser beam and the control system, enabling automatic monitoring while keeping the laser system configuration simple.
3Measurement precision
If additional laser source is used for monitoring, then wire position can be detected, but system cost and complexity increase
Solution Approach 1:
The patent makes the primary laser beam serve dual functions: both brazing processing and wire position monitoring. By using the same laser beam for both purposes, the system eliminates the need for separate auxiliary laser sources while achieving automatic monitoring capability. This multi-functionality approach reduces device complexity while maintaining automation.
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 reliable and automatic monitoring of the braze wire position, reducing measurement faults and improving productivity by eliminating the need for manual inspections and additional laser sources.
Implementation Method 1
An optical detector is arranged to detect laser light being reflected from the wire
Implementation Method 2
By the provision of a jig which shields off the wire while at the same time blocks a part of the emitted laser beam
Data Source
AI summary
The invention relates to a laser brazing system, comprising a braze tool having a laser configured to emit a laser beam along a radiation path, and a braze wire tool being configured to guide a braze wire along a wire path intersecting the laser beam. The system comprises a jig comprising a first alignment surface and a first blocking surface, wherein the first alignment surface is configured to be in contact with the braze wire while the first blocking surface blocks at least a first part of the emitted laser beam, and a detector arranged in the radiation path and configured to detect the emitted light of the laser beam passing the jig.