Laser Wire Welding Feedback Control for Burnback Prevention
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Solution Overview
Problem
In wire-based welding methods, especially laser-based processes, achieving accurate initial positioning of the wire-shaped filler is challenging due to issues like burnback and bird-nesting, which disrupt the process by causing irregularities in wire contact with the workpiece.
Innovation Solution
A method where the wire-shaped filler and laser beam are used in conjunction with an electrical circuit to monitor and control the wire feed movement and laser power based on electrical voltage, current, and resistance measurements, ensuring continuous contact and preventing burnback by adjusting the laser power or switching it off when threshold values are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire feed speed is increased to improve productivity, then welding speed increases, but wire positioning accuracy deteriorates causing burnback or bird-nesting
Solution Approach 1:
The patent implements a feedback control system using electrical contact sensing between the wire and workpiece. When the wire loses contact (bird-nesting) or makes excessive contact (burnback), the electrical circuit detects this state and automatically adjusts the wire feed speed to maintain proper positioning, enabling high welding speeds without sacrificing positioning accuracy
Solution Approach 2:
The patent replaces mechanical wire positioning sensors with an electrical contact detection system. By monitoring electrical continuity between the wire and workpiece, the system achieves more reliable and responsive detection of wire positioning states compared to traditional mechanical sensing methods
2Manufacturing precision
If wire feed mechanism is made more precise to maintain wire contact, then wire positioning accuracy improves, but device complexity increases
Solution Approach 1:
The electrical contact detection system provides continuous feedback on wire positioning status, allowing the control system to make real-time adjustments to wire feed speed. This feedback loop maintains stable wire contact without requiring overly complex mechanical feed mechanisms
Solution Approach 2:
The system dynamically changes the wire feed speed parameter based on electrical contact detection. When contact is lost, feed speed is reduced; when contact is excessive, feed speed is increased. This dynamic parameter adjustment maintains wire contact stability without adding mechanical complexity
3Reliability
If laser power is continuously applied to maintain fusion, then welding quality improves, but risk of burnback increases when wire contact is poor
Solution Approach 1:
The electrical contact detection system provides feedback on wire-to-workpiece contact status. When contact is detected, laser power is applied for fusion; when contact is lost, laser power is reduced or interrupted. This feedback control maintains welding quality while preventing burnback by matching laser power application to actual wire contact conditions
Solution Approach 2:
The system takes preliminary anti-action by detecting potential burnback conditions through electrical contact monitoring and preemptively adjusting laser power before burnback occurs. This prevents the harmful effect rather than correcting it after occurrence
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 method ensures stable wire contact and prevents defects by automatically adjusting the laser power and feed movement, maintaining a smooth welding process and avoiding wire jamming and burnback.
Implementation Method 1
The wire-shaped filler and the material are connected to an electrical voltage source and form an electrical circuit. The electrical voltage, the electrical current and/or the electrical resistance in the electrical circuit are measured and used as control variable or variables
Implementation Method 2
Wire-shaped filler is advanced in the direction of the surface of the workpiece by means of an accordingly designed wire feed mechanism and is successively fused during the feed movement in the area of the wire-shaped filler that is arranged directly above the particular surface, using the energy of the at least one laser beam
Data Source
AI summary
In a method for welding using a wire-shaped filler and at least one laser beam, the wire-shaped filler is advanced in the direction of the surface of the workpiece by a wire feed mechanism. The wire-shaped filler is successively fused during the feed movement thereof. The wire-shaped filler and the material are connected to an electrical voltage source and form an electrical circuit. The electrical voltage, the electrical current and/or the electrical resistance are measured and used as control variables for the wire feed movement and/or the power of the at least one laser beam. Use of the laser beam is modified when a predefined threshold value of the electrical voltage and/or of the electrical current are fallen short of or a predefined threshold value of the electrical resistance is exceeded.