Modular Laser Welding System for Inward Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing overlay welding systems face challenges in achieving flexible and independent processing of inwardly disposed surfaces of workpieces with variable immersion depth and direction, particularly due to difficulties in homogeneous powder feed and adaptation to different geometries.
Innovation Solution
A modular system comprising a feed for powdery welding material, protective gas, and coolant, along with a coupling and beam-guiding module for a collimated laser beam, allowing for variable immersion depth and direction through interchangeable modules and focusing elements, enabling precise and adaptable processing of inwardly disposed surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a static apparatus is used for inwardly disposed surfaces with pipe rotation, then processing independence of direction is achieved, but adaptation to different workpiece geometries requires very increased effort
Solution Approach 1:
The system is divided into modular components including a coupling module, beam-guiding modules of different lengths, and processing modules that can be connected and disconnected. This segmentation allows easy adaptation to different workpiece geometries by selecting appropriate module combinations while maintaining processing independence of direction through the modular architecture.
Solution Approach 2:
The system transitions from a static apparatus to a dynamic modular system where beam-guiding modules can be selectively connected and disconnected. This dynamic reconfiguration capability enables adaptation to different workpiece geometries while preserving the independence of direction feature through controlled module assembly.
2Productivity
If powdery welding material is supplied from one or two sides via separate powder feeds, then overlay welding can be performed, but homogeneous powder feed into the focal spot region is not easily achieved and feeds are exposed to heat and particles
Solution Approach 1:
Multiple powder feed passages are merged into a single integrated processing module that delivers powder uniformly into the focal spot region. This consolidation eliminates the problems of separate feeds being exposed to heat and particles while achieving homogeneous powder distribution through a unified delivery system.
Solution Approach 2:
The processing module acts as an intermediary between the powder feed sources and the workpiece, providing a protected environment that shields the feed system from heat and particles while ensuring homogeneous powder delivery to the focal spot region through controlled passage design.
3Adaptability or versatility
If beam-guiding modules of different lengths are used, then variable immersion depth is enabled, but system complexity increases
Solution Approach 1:
The coupling module and processing module serve as universal components that work with beam-guiding modules of different lengths. This multi-functionality approach enables variable immersion depth through simple module selection rather than complex internal adjustments, reducing overall system complexity while maintaining versatility.
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 modular system facilitates flexible and independent processing of inwardly disposed surfaces with improved powder feed and laser beam directionality, enabling efficient coating of workpieces with variable immersion depth and adaptable to different geometries, enhancing processing flexibility and quality.
Implementation Method 1
A collimated laser beam is directed via the coupling module through the beam guiding module(s) onto an optical element focusing the laser beam on the surface of a workpiece to be processed
Implementation Method 2
overlay welding using laser radiation
Implementation Method 3
Powdery welding material is, as a rule, supplied from one side, but optionally also from two sides, via one or two separate powder feeds
Implementation Method 4
it is customary to align the laser beam and additionally a protective gas onto the respective processing region
Data Source
AI summary
The invention relates to a modular system for overlay welding at inwardly disposed surfaces of workpieces using a laser beam. In this respect, a coating can be formed on inwardly disposed surfaces using a powdery welding material. It is the object of the invention to provide possibilities for the overlay welding or for the coating of inwardly disposed surfaces of workpieces with a variable immersion depth, increased flexibility and independence of direction in the processing. A feed for powdery welding material, a feed for protective gas and a feed for a coolant are present on a system in accordance with the invention. The system is formed with a coupling module for the laser beam, at least one beam guiding module for the laser beam and a processing module, which can be connected to one another. A collimated laser beam is directed via the coupling module through the beam guiding modules) onto an optical element focusing the laser beam on the surface of a workpiece to be processed. A nozzle having a discharge opening for the laser beam and the protective gas as well as a passage having a discharge opening for powdery welding material are present at the processing module.