Simultaneous Multi-Point Laser Welding Distortion Control
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Solution Overview
Problem
Thermal joining of metallic components often results in distortion, making it difficult to maintain specified structural dimensions and tolerances due to residual stresses and heat input, which existing methods fail to adequately address.
Innovation Solution
Simultaneous welding at spatially spaced joints, preferably using laser welding or metal protective gas welding, with components held in place by contact force during and after welding, to minimize distortion and residual stresses, potentially using robot arms for parallel processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal joining (welding) is used to connect metallic components, then strong structural connection is achieved, but distortion and residual stresses occur making it difficult to maintain dimensional accuracy and tolerances
Solution Approach 1:
The welding process is segmented into multiple simultaneous welding operations at different joints. Instead of welding one joint at a time, the method divides the welding task across multiple joints that are welded simultaneously, distributing the thermal load and preventing concentrated distortion at any single location.
Solution Approach 2:
The method employs periodic or simultaneous welding actions at multiple joints rather than continuous sequential welding. By alternating or simultaneously welding at different joints, the thermal cycles are distributed in time and space, allowing residual stresses to balance out and preventing cumulative distortion.
2Reliability
If sequential welding at single joints is performed, then welding quality can be controlled, but production time and efficiency are reduced
Solution Approach 1:
Multiple welding operations that would traditionally be performed sequentially are merged into simultaneous operations. The method combines several welding processes occurring at the same time at different joints, thereby multiplying productivity while maintaining quality control through coordinated process management.
Solution Approach 2:
The welding process achieves continuous useful action by eliminating idle time between welding operations. While traditional sequential welding has downtime while moving between joints, this method maintains continuous welding activity across multiple joints simultaneously, maximizing equipment utilization and production efficiency.
3Productivity
If high heat input is used for welding, then welding speed and productivity increase, but distortion and residual stresses increase
Solution Approach 1:
The method applies local quality by distributing heat input across multiple local joints simultaneously rather than concentrating high heat input at a single location. Each joint receives controlled heat input appropriate for its specific requirements, preventing excessive thermal accumulation that would cause distortion while maintaining overall 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
This method effectively minimizes distortion and residual stresses in welded connections, improving dimensional accuracy and reducing production costs by allowing for efficient, high-quality welding of metallic components with reduced energy consumption and additive use.
Implementation Method 1
Particularly in the case of technically high-quality components and in relatively high quantities, such as switching elements of manual transmissions, it can be economically advantageous to carry out the simultaneous welding processes using a laser welding process.
Implementation Method 2
Furthermore, it can be advantageous if the components to be welded are held in their positions by the pressure of a contact force after they have been joined, at least during the welding process and at least in their joining area.
Data Source
Figure 1~2
AI summary
In a process for joining, in particular, metallic components (1, 2) by means of at least one welding operation, the components (1, 2) are first moved together or joined together and then welded to one another at at least two joining points (2, 3) in different locations at the same time, preferably by means of a laser welding process and under the control of a robot.