Laser-Wire Welding Head With Pyramid Optics for Easier Beam Alignment
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Solution Overview
Problem
Existing laser processing heads for wire build-up welding face challenges in achieving precise and homogeneous optical adjustment, particularly during continuous operation, due to the complexity and error-prone nature of aligning the laser beam and optical fiber with reflecting elements.
Innovation Solution
A laser processing head design featuring a pyramid-shaped element with aligned reflecting surfaces that direct partial beams onto a common plane, where the optics carrier element is adjustable and lockable, simplifying the optical adjustment to a single axis, and incorporating a monolithic optics carrier made of copper or copper alloy with cooling channels for thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate optical elements are used for beam reflection and wire feeding, then the laser beam can be directed onto the wire-shaped material, but the alignment becomes complex and error-prone requiring adjustment at multiple positions
Solution Approach 1:
The patent combines multiple separate optical elements (beam deflecting reflecting elements, wire feed mechanism, and positioning system) into a single integrated optics carrier element. This element includes a pyramid-shaped structure with reflecting surfaces and integrated wire feeding means, eliminating the need for separate alignment of multiple components and reducing adjustment complexity to a single position.
2Productivity
If traditional separate optical elements are used, then beam reflection can be achieved, but repeated adjustments are needed during continuous operation increasing loss of time
Solution Approach 1:
The optics carrier element is designed with adjustable and lockable positioning capabilities that allow dynamic adjustment during continuous operation. The element can be repositioned and locked at new positions without requiring disassembly or complex realignment procedures, enabling quick adjustments while maintaining continuous production flow.
3Reliability
If multiple separate optical elements require alignment, then the laser beam can be properly directed, but the adjustment process becomes prone to errors reducing reliability
Solution Approach 1:
By integrating the wire feed mechanism and beam reflecting surfaces into a single optics carrier element with unified positioning, the patent eliminates the need for separate alignment of multiple components. This reduces adjustment operations from multiple positions to a single integrated adjustment, significantly reducing error probability and improving reliability.
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 design enables simplified and accurate optical adjustment, ensuring homogeneous heating and material utilization, reducing operational complexity and minimizing errors, while maintaining precise control over wire feed and beam alignment.
Implementation Method 1
a pyramid-shaped element (8) is incident on by the laser beam (6) and in doing so onto at least three reflecting surfaces (8.1) of the pyramid-shaped element (8)
Implementation Method 2
The reflecting surfaces (8.1, 8.2) are formed on a monolithic optics carrier element (5.1) made of copper or copper alloy
Data Source
AI summary
A laser beam is directed onto a pyramid-shaped element, wherein the beam is directed onto at least three reflecting surfaces and the respective reflected partial beams are incident on reflecting surfaces arranged on an optics carrier element. The partial beams are aligned such that they intersect in a common plane. An internal wire feed is arranged in a housing, having an outlet nozzle for a fusible wire-shaped material, which material is using the energy of the partial beams. The outlet nozzle is arranged in front of the plane in which the reflected partial beams intersect. The pyramid-shaped element and the reflecting surfaces are formed on a carrier element, which is arranged in such a way that it is displaceable following the outlet nozzle in two perpendicular directions to the optical axis of the laser beam or perpendicular to the central longitudinal axis of the wire-shaped material.