Laser Filler Wire Preheating Inside a Shielded Feed Channel
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Solution Overview
Problem
Existing welding devices that use laser beams to heat filler materials pose safety concerns due to the need for laser safety measures, and alternating current heating systems affect the welding arc, reducing efficiency and productivity.
Innovation Solution
A welding device with a pre-heater and deflector system that directs the laser beam inside a closed feed channel for the filler material, eliminating the need for safety precautions and minimizing magnetic interference, using a deflector such as a mirror or prism to focus or fan out the beam, and an optical waveguide to transport the laser light efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser beam is directed to the weld without shielding, then the melting performance of the filler material is improved and productivity is increased, but laser safety measures must be taken making the system unsuited for manual welding torches
Solution Approach 1:
The feed channel acts as an intermediary component that guides the laser beam to the filler material. The deflector positioned within the feed channel serves as a mediator to redirect the laser beam onto the filler material surface, enabling heating while containing the laser path within the torch structure and preventing direct exposure to the user.
Solution Approach 2:
The deflector is integrated within the feed channel structure, creating a nested arrangement where the laser beam path is contained within the feed channel. This nesting ensures the laser beam remains confined to the internal geometry of the torch, eliminating the need for external safety shielding.
2Temperature
If alternating current is applied to heat the filler material, then the filler material is heated, but the magnetic field generated repels and/or attracts the welding arc affecting the welding point
Solution Approach 1:
The patent replaces the electrical heating method (alternating current) with an optical heating method (laser beam). This substitution eliminates the generation of magnetic fields that would interfere with the welding arc, while still achieving the desired heating of the filler material through photothermal conversion.
Solution Approach 2:
The heating method is changed from electrical (current-based) to optical (laser-based), fundamentally altering the physical parameter used for heating. This parameter change eliminates magnetic field generation while maintaining the thermal heating function needed to improve filler material melting performance.
3Use of energy by moving object
If the laser device is arranged at a suitable location and the laser beam is directed to the desired location on the filler material, then the heating efficiency is improved, but the device complexity increases
Solution Approach 1:
The feed channel serves multiple functions: it guides the filler material to the weld, contains the laser beam path, and provides mounting structure for the deflector. This multi-functionality reduces the need for additional dedicated components, thereby limiting the increase in device complexity while achieving effective laser heating.
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 solution enhances the melting performance of the filler material, allowing for improved gap bridgeability and higher welding speeds while maintaining user safety and reducing the impact on the welding arc.
Implementation Method 1
a pre-heater for heating the filler material upstream of the weld by means of a laser beam having a laser power and generated in a laser device
Implementation Method 2
the laser beam strikes the filler material inside the feed channel of the pre-heater
Implementation Method 3
at least one deflector for deflecting the laser beam to the filler material being attached to the pre-heater in such a way that the laser beam strikes the filler material inside the feed channel
Data Source
AI summary
The invention relates to a welding device (1) having a welding torch (2), a feeder (3) for feeding a melting filler material (4) at a feed rate (v) to a weld (S), where the filler material (4) is melted with the aid of an electric arc (L), and a pre-heater (9) for heating the filler material (4) upstream of the weld (S) by means of a laser beam (7) having a laser power (P) and generated in a laser device (6). For space-saving and safe heating of the filler material (4) upstream of the weld (S), the pre-heater (9) includes a feed channel (5) for the filler material (4), and at least one deflector (8) is attached to the pre-heater (9) for deflecting the laser beam (7) to the filler material (4) in such a way that the laser beam (7) strikes the filler material (4) inside the feed channel (5) of the pre-heater (9).