Laser Wobble Path Compensation for High-Frequency Weld Accuracy

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Solution Overview

Problem

Conventional 2D scanner systems for superimposing wobble movements on laser beam machining paths experience figure reproduction errors due to changes in size and geometry at higher wobble frequencies, leading to inaccuracies in weld seam formation and melt pool dynamics.

Innovation Solution

A system that uses a deflection device and wobble device to control the laser beam's movement with compensated wobble movements, adapting control values and path speeds as functions of wobble frequency and position to minimize figure reproduction errors, allowing for precise control of the wobble figure even at high frequencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wobble frequency is increased to improve machining speed, then productivity increases, but figure reproduction accuracy deteriorates due to size and geometry changes in the wobble figure

Engineering Contradiction:

Improvemachining speedVSAvoidfigure reproduction accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary calculation of compensated control values before executing the wobble movement. The control values are pre-adjusted based on the relationship between wobble frequency and figure reproduction errors, allowing the system to maintain accurate wobble figures even at high frequencies without real-time complex computations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the control parameters (control values for deflection device) based on wobble frequency. By adapting the control values as a function of wobble frequency, the system compensates for frequency-dependent figure reproduction errors and maintains manufacturing precision across different productivity levels

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If conventional 2D scanner systems are used to superimpose wobble movements, then device complexity is reduced, but manufacturing precision deteriorates due to figure size and geometry changes at higher frequencies

Engineering Contradiction:

Improvescanner system complexityVSAvoidwobble figure accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system implements a feedback mechanism where figure reproduction errors are measured and used to calculate compensated control values. The control system continuously adjusts the deflection device control values based on the relationship between wobble frequency and observed errors, maintaining accurate wobble figures without requiring complex hardware modifications

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces mechanical solutions for maintaining figure accuracy with a control-theory-based approach. Instead of using complex mechanical compensation mechanisms, the system uses calculated control values to electronically compensate for figure reproduction errors, reducing device complexity while maintaining precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enhances figure accuracy and scalability of process parameters, enabling increased wobble frequencies while maintaining weld seam quality, and allows for specific influence on melt pool dynamics, thereby optimizing machining speed and precision.

Implementation Method 1

a deflection device for deflecting the laser beam; and a wobble device configured to superimpose a wobble movement of the laser beam

Methodology Applied

Scientific EffectLaser beam deflection:

Data Source

PatentUS20220234136A1Material processing by means of a laser beam in a wobble movement

Publication Date: 2022.07.28 PRECITEC GMBH

AI summary

A system for machining materials by means of laser beam includes a deflection device for deflecting the laser beam and a wobble device configured to superimpose a wobble movement of the laser beam with a wobble figure and a wobble frequency onto a feed movement of the laser beam corresponding to a machining path by controlling the deflection device. The wobble device is configured, for carrying out the wobble movement, to control the deflection device according to a compensated wobble movement. Control values for a deflection of the laser beam along the wobble figure are adapted as a function of the wobble frequency and/or a path speed of the wobble movement that varies along the wobble figure is adapted as a function of a position of the laser beam in the wobble figure and as a function of the wobble frequency.