Laser Beam and Wire Wobble for Arc-Like Heat Distribution
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Solution Overview
Problem
Conventional laser welding systems pose challenges for new users due to the need for adapting from arc welding techniques, particularly in achieving quality welds and incorporating laser protection features, and existing laser systems struggle to spread heat effectively beyond scanning alone.
Innovation Solution
The integration of a beam expanding optic and wobble generator in laser welding systems to widen the focal point and move the laser beam and/or wire, mimicking the heat distribution of traditional arc welding systems, along with user interfaces for controlling wobble patterns and movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional laser welding system uses a focused laser beam with a small focal point, then welding precision and heat concentration are improved, but the ability to spread heat effectively is reduced
Solution Approach 1:
The patent implements dynamic control of the laser beam focal point through scanning and wobble mechanisms. The focal point is no longer static but moves dynamically across the workpiece surface, allowing the concentrated heat to be distributed effectively while maintaining the precision benefits of laser welding. This resolves the contradiction by making the heat application both concentrated (when focused) and distributed (when scanned/wobbled).
Solution Approach 2:
The patent employs periodic scanning and wobble motions of the laser beam focal point. By oscillating the focal point in controlled patterns, the system achieves periodic heat application that spreads heat effectively across the weld area while maintaining the high energy density characteristic of laser welding. This periodic motion transforms the static focused beam into a dynamic heat distribution system.
2Device complexity
If a laser welding system operates without wobble or scanning mechanisms, then system complexity is reduced, but the ability to achieve quality welds comparable to arc welding is compromised
Solution Approach 1:
The patent introduces dynamic scanning and wobble mechanisms to control the laser focal point position. These mechanisms add controlled motion capabilities to the laser system, enabling it to replicate the heat distribution patterns of traditional arc welding while maintaining laser welding advantages. The dynamic control allows the system to achieve quality welds without excessive complexity by using programmable motion patterns.
Solution Approach 2:
The patent implements control systems that monitor and adjust the laser focal point position in real-time. Through feedback control, the system maintains precise focal point positioning during scanning and wobble operations, ensuring consistent weld quality. The feedback mechanism compensates for variations in material properties, joint geometry, and processing conditions, enabling the system to achieve arc-weld-comparable quality with controlled complexity.
3Ease of operation
If a laser welding system uses a fixed focal point, then the system is easier to operate, but new users struggle to adapt from arc welding techniques
Solution Approach 1:
The patent implements scanning and wobble patterns that replicate the heat distribution characteristics of traditional arc welding processes. By copying the effective heat application patterns of arc welding, the system allows users familiar with arc techniques to transfer their skills to laser welding. The focal point motion patterns mimic the natural movement and heat spread of arc welding, making the transition easier for new users while maintaining operational simplicity through automated control.
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
Enhances the ability of laser welding systems to perform like traditional arc welding by spreading heat effectively, improving weld quality and appearance, and facilitating adaptation for users familiar with arc welding.
Implementation Method 1
The system includes a beam expanding optic to widen a focal point of the laser beam as applied to the workpiece
Implementation Method 2
a wobble generator to move the laser beam and/or the wire as applied to the workpiece
Implementation Method 3
The laser beam provides a concentrated heat source, enabling a precise control of the heat input
Data Source
AI summary
Systems and methods for laser welding are disclosed. A laser welding system includes a handheld or robotic laser welding tool to direct laser power to a workpiece to generate a weld during a laser welding operation. The welding system includes a wobble generator (e.g., a beam wobble optic, a wire guide optic, and/or a mechanical controller/oscillator) to move the laser beam and/or the wire as applied to the workpiece.