Laser Beam and Wire Wobble for Better Heat Distribution in Welding
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Solution Overview
Problem
Conventional laser-based welding systems pose challenges for new users due to the need for adapting to unfamiliar laser welding techniques, particularly in achieving quality welds and incorporating laser protection features, and existing systems struggle to distribute heat effectively beyond scanning alone.
Innovation Solution
Incorporating a beam expanding optic and wobble generator into laser welding systems to widen the focal point and move the laser beam and/or wire, mimicking traditional arc welding by enhancing heat distribution and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional laser beam with a small focal point is used, then welding precision and speed are improved, but heat distribution is limited and the system is difficult for new users to operate
Solution Approach 1:
The patent applies mechanical vibration through a wobble generator that oscillates the laser beam and/or wire at controlled frequencies. This vibration mechanism distributes heat more effectively across the workpiece surface, mimicking the heat distribution characteristics of traditional arc welding while maintaining laser welding precision and speed advantages
Solution Approach 2:
The patent introduces a wobble generator as an intermediary component between the laser source and workpiece. This device mediates the interaction by adding controlled oscillation to the laser beam path, enabling new users to achieve quality welds through automated heat distribution without requiring extensive knowledge of laser welding techniques
2Productivity
If laser beam scanning is used to distribute heat, then welding speed is maintained, but heat distribution effectiveness is insufficient compared to traditional arc welding
Solution Approach 1:
The wobble generator creates mechanical oscillation of the laser beam at frequencies and amplitudes that enhance heat penetration and distribution into the workpiece. This vibration-based heat distribution method maintains high welding speed while achieving superior heat penetration compared to conventional scanning methods
Solution Approach 2:
The patent implements periodic oscillation of the laser beam through the wobble generator, creating a rhythmic pattern of heat application. This periodic action allows the laser energy to penetrate and distribute heat more effectively throughout the material, mimicking the thermal characteristics of arc welding while maintaining laser welding productivity
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
The solution allows for improved heat spreading and distribution, enabling laser welding systems to perform more like traditional arc welding, resulting in enhanced weld quality and appearance.
Implementation Method 1
Incorporating a beam expanding optic and wobble generator into laser welding systems to widen the focal point
Implementation Method 2
wobble generator to move the laser beam and/or wire, mimicking traditional arc welding by enhancing heat distribution and control
Implementation Method 3
Laser welding is a welding technique used to join multiple pieces of metal through the use of a laser. The laser beam provides a concentrated heat source, enabling a precise control of the heat input
Data Source
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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.