Modular Welding Head Assembly for Flexible Multi-Torch Layout
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Solution Overview
Problem
Current hybrid laser welding devices face challenges with the management of welding wire and supporting service lines, leading to large and cumbersome welding head assemblies, and limited adjustability and space constraints for multiple torches and gas shielding in close proximity.
Innovation Solution
A modular welding head assembly composed of interconnectable functional blocks for distributing welding wire, gas, and cooling fluid, allowing for customizable configurations and improved placement of components, including laser beam, welding wire, gas, and cooling water delivery blocks, with optional sensor blocks for enhanced precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple welding wires, gas shielding, and cooling lines are integrated into a single welding head, then welding functionality is improved, but the size and complexity of the welding head assembly increases
Solution Approach 1:
The welding head assembly is divided into separate modular components including a laser handpiece module, a wire feed module, gas delivery modules, and cooling fluid delivery modules. Each module can be independently configured and assembled, allowing complex welding functionality to be achieved through combination of simpler individual components rather than integrating everything into a single complex assembly.
2Productivity
If multiple welding torches are placed in close proximity, then welding efficiency is improved, but space constraints and interference between torches increase
Solution Approach 1:
By separating the welding system into modular components (laser handpiece, wire feed modules, gas delivery modules), multiple torches can be configured with optimized spacing and orientation. Each module can be positioned independently to minimize interference between adjacent torches while maintaining close proximity for efficient multi-torch welding operations.
3Device complexity
If a monolithic torch design is used, then structural simplicity is improved, but adjustability of component placement and work angles is limited
Solution Approach 1:
The modular architecture allows dynamic reconfiguration of the welding head assembly. Individual modules can be adjusted, repositioned, and reoriented relative to each other to optimize component placement and work angles for different welding applications, providing adaptability that fixed monolithic designs cannot achieve.
Solution Approach 2:
The separation into modular components enables independent adjustment of each module's position and orientation. This segmentation allows the system to adapt to various welding configurations and angles while maintaining structural simplicity within each individual module.
4Device complexity
If welding wire and service lines are managed in a traditional integrated manner, then connection simplicity is improved, but maneuverability of the welding head deteriorates
Solution Approach 1:
By separating wire feed, gas delivery, and cooling fluid delivery into individual modular modules, each with its own connection interfaces, the system achieves both connection simplicity and improved maneuverability. Each module can be independently positioned and connected, reducing the bulk and complexity of integrated traditional designs while maintaining straightforward connection procedures.
Data Source
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AI summary
The present disclosure relates to a system of modular functional blocks that may be used to facilitate easy assembly of a welding head assembly in any one of a wide variety of configurations to allow for distribution of welding wire, gas, cooling fluid and other media throughout an interconnected assembly of the modular functional blocks. As such, the modular functional blocks can be mixed and matched into any desired configuration as needed depending on the welding process being undertaken. The modular functional blocks may be in the form of one or more different welding wire delivery blocks, gas delivery blocks, cooling water delivery blocks, shim plates, end plates, shield cup, cover plates, insulating plates, etc.