Fixed Multi-Reflector Laser Welding for 360° Circumferential Welds
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Solution Overview
Problem
Current laser-welding methods for tubular components in medication delivery devices face challenges in achieving consistent 360° circumferential welds without requiring extensive pre-adjustment or calibration, especially in high-production settings, due to complex optical systems and time-consuming adjustments.
Innovation Solution
A single, fixed optical reflector with multiple angled surfaces, configured at an obtuse angle, is used to direct a laser beam around a workpiece, allowing only vertical adjustment of the workpiece relative to the reflector for setup, eliminating the need for lateral and angular adjustments, and enabling a stationary laser source and workpiece during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple adjustable optical reflectors are used to redirect the laser beam onto inaccessible areas, then the laser beam can reach all areas of the workpiece, but the setup becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple optical reflector surfaces into a single integrated optical assembly. Instead of using separate adjustable reflectors, the invention integrates multiple reflecting surfaces (first optical surface, second optical surface, third optical surface) onto one fixed assembly, eliminating the need for multiple independent components and their associated adjustment mechanisms.
Solution Approach 2:
The optical reflector assembly is pre-configured with specific angles and orientations during manufacturing. The first optical surface is angled at 45 degrees to the laser beam path, the second optical surface is angled to redirect the beam onto the bottom surface, and the third optical surface is positioned to redirect the beam onto lateral surfaces. This preliminary configuration eliminates the need for time-consuming on-site adjustments.
2Manufacturing precision
If adjustable optical reflectors are used to achieve uniform heating, then consistent weld quality can be achieved, but the adjustment process is time-consuming and error-prone
Solution Approach 1:
The optical reflector assembly is pre-configured with specific angles and orientations during manufacturing. The first optical surface is angled at 45 degrees to the laser beam path, the second optical surface is angled to redirect the beam onto the bottom surface, and the third optical surface is positioned to redirect the beam onto lateral surfaces. This preliminary configuration eliminates the need for time-consuming on-site adjustments.
Solution Approach 2:
The fixed optical reflector assembly is designed to automatically provide the correct beam redirection angles and positions without requiring operator intervention for adjustment. The system is self-configuring, eliminating human error and variability in the setup process while maintaining consistent weld quality.
3Productivity
If a stationary laser source is used with a fixed optical reflector, then the manufacturing process is simplified and throughput is increased, but the laser beam must reach inaccessible areas
Solution Approach 1:
The optical reflector assembly is segmented into multiple functional surfaces, each responsible for directing the laser beam to specific areas. The first optical surface handles the primary beam direction, the second optical surface handles the bottom surface, and the third optical surface handles lateral surfaces, allowing the stationary system to cover all necessary areas.
Solution Approach 2:
The patent uses multiple optical surfaces positioned at different angles and locations to redirect the laser beam in three-dimensional space. By utilizing vertical angles (45 degrees), horizontal redirections, and multi-surface reflections, the system achieves circumferential coverage without moving the laser source, effectively adding spatial dimensions to the beam path.
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 results in high-quality, consistently uniform 360° circumferential welds with reduced setup time and increased throughput, minimizing variability and setup errors in high-production settings.
Implementation Method 1
an optical reflector assembly having at least two angled mirrors positioned to direct the laser beam passing around the workpiece to reach areas of the workpiece that are not directly in the path of the laser beam
Data Source
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AI summary
Device and method for laser welding around a circumference of a workpiece. A fixed, non-movable unitary optical reflector has a pair of optical reflecting surface portions on a first side surface and a second side surface, respectively, arranged at an obtuse angle relative to each other. A workpiece is fixed in an assembly having the reflector. During setup, the vertical distance is adjusted between the reflector and workpiece along an axis that is transverse to a longitudinal axis thereof without any adjustment of the reflecting surfaces. The first and second side surfaces define a curve that is transverse to the longitudinal axis. Once setup has been completed, a laser beam is directed so that it moves along the optical reflector to thereby produce a 360 degree circumferential weld around the workpiece. Another assembly is provided to change the laser beam direction multiple times to irradiate a circumference of a fixed workpiece from a fixed laser source.