Multi-Nozzle Laser Head for Low-Downtime Hybrid Processing
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Solution Overview
Problem
Current laser processing systems face challenges in reducing production downtime, maintaining optical performance, and achieving precise and efficient multi-functional operations, particularly in additive and subtractive manufacturing, due to limitations in flexibility, nozzle encumbrance, and increased costs associated with multiple laser heads and nozzles.
Innovation Solution
A modular laser-processing apparatus with a flexible laser head equipped with adjustable nozzles and dual-core optical fibers, allowing for simultaneous control of laser beams and nozzle positions, enabling flexible operation across various processing types, including DED additive manufacturing, welding, and cutting, while minimizing downtime and optimizing nozzle positioning for reduced encumbrance and improved precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specialized laser heads are used for different processing operations, then processing capability and versatility are improved, but production downtime increases due to frequent head replacements and recalibration
Solution Approach 1:
The patent implements a single laser head that can perform multiple processing operations (welding, cutting, additive manufacturing) by integrating multiple nozzles with different functions. The laser head includes a welding nozzle, a cutting nozzle, and an additive manufacturing nozzle, allowing the system to switch between operations without physical head replacement, thereby eliminating production downtime while maintaining versatility
Solution Approach 2:
The patent combines multiple specialized nozzles (welding nozzle, cutting nozzle, additive manufacturing nozzle) into a single integrated laser head assembly. This merging of previously separate tools into one unified device enables the system to perform multiple operations sequentially without removal or replacement, resolving the contradiction between versatility and production continuity
2Adaptability or versatility
If multiple laser heads with nozzles are used for different operations, then processing versatility is improved, but device complexity and costs increase
Solution Approach 1:
The patent creates a universal laser head that handles welding, cutting, and additive manufacturing operations through a single integrated design. By making the laser head multi-functional, the system reduces the number of separate devices needed, thereby reducing overall system complexity and cost while maintaining processing versatility
Solution Approach 2:
The patent merges multiple specialized nozzles and their associated delivery systems into one integrated laser head assembly. This consolidation reduces the number of separate components, simplifies the overall system architecture, and lowers costs while preserving the ability to perform multiple processing operations
3Manufacturing precision
If nozzles are positioned close to the work surface for precision, then processing precision is improved, but nozzle encumbrance and interference increase
Solution Approach 1:
The patent positions the nozzles in a retracted position when not in use, utilizing the vertical dimension to clear the work area. During active operations, the nozzles are extended to the required proximity for precision processing. This dimensional positioning strategy allows the system to achieve high precision when needed while minimizing encumbrance during transitions and idle periods
4Adaptability or versatility
If frequent tool changes are implemented for different operations, then operational flexibility is improved, but production efficiency decreases
Solution Approach 1:
The patent implements a universal laser head capable of performing welding, cutting, and additive manufacturing operations without requiring tool changes. The system achieves operational flexibility through software control and nozzle selection rather than physical tool replacement, thereby maintaining adaptability while continuously producing without interruption, thus improving production efficiency
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 enables reduced production downtime, improved precision, and increased productivity by allowing a single laser head to perform multiple processing operations without the need for frequent tool changes, maintaining optical performance, and reducing costs through modular flexibility and adjustable nozzle configurations.
Implementation Method 1
a laser head, which can be operated as end tool of a laser machine tool that can be configured for carrying out at least one type of laser processing operation
Implementation Method 2
direct-energy-deposition (DED) additive manufacturing, cladding, or (wire or powder) welding
Implementation Method 3
a set of orientable optical components so as to provide a set of selectable optical paths for directing a laser beam
Implementation Method 4
directing a laser beam supplied by a respective laser source onto a region of a work surface
Data Source
Figure 1
Figure 2~3
Figure 3A~3B
AI summary
The present application relates to an apparatus (10) for laser processing, comprising at least two laser sources (12, 14), which are different from one another and are configured for supplying respective laser beams having wavelengths different from one another, a laser head (20), which can be operated as end tool of a laser machine tool (90) that can be configured for carrying out at least one type of laser processing operation that can be selected from a set of types of laser processing operations, and a set of orientable optical components (16) so as to provide a set of selectable optical paths for directing a laser beam supplied by a laser source of said at least two laser sources, and a control unit (30) coupled to the at least two laser sources (12, 14), to the set of orientable optical components (16), and to the laser head (20) and configured for controlling the at least two laser sources (12, 14), the set of orientable optical components (16), and the laser head (20) according to the type of laser processing operation selected from the set of types of laser processing operations, i.e., so as to supply and direct a laser beam associated to the respective type of processing operation onto a region of a work surface (110). The laser head (20) comprises a set of nozzles (40, 42, 44, 46) configured for directing at least one processing material onto the working region (110), which comprises at least one nozzle (40) configured for directing jets of powder of at least one material, preferably powder of metal material (in brief metal powder), as well as comprising at least one of the following: a) a first nozzle (42) configured for directing a metal wire onto the working region, preferably metal wire for laser welding; and b) a second nozzle (46) configured for directing an assist gas onto the working region, preferably an assist gas for laser welding, and wherein the control unit (30) is coupled to the set of nozzles and is configured for controlling at least one nozzle of said set of nozzles (40, 42, 44, 46) according to the type of associated and selected laser processing operation so as to control said at least one nozzle so that it will direct respective processing materials onto the working region (110) simultaneously with direction of the laser beam (L) associated to the type of laser processing operation selected.