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 and high-quality 360° circumferential welds without requiring extensive pre-adjustment or calibration, especially in high-production settings, due to the complexity of optical systems and the need for precise angular alignment of reflectors.
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 tubular workpiece, allowing only vertical adjustment of the workpiece relative to the reflector, eliminating the need for lateral and angular adjustments, and enabling a 'set it and forget it' configuration for consistent 360° circumferential welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single, fixed optical reflector with multiple angled surfaces is used to direct laser beam around workpiece, then manufacturing precision and consistency of weld quality is improved, but device complexity increases due to the fixed reflector configuration
Solution Approach 1:
The optical reflector is segmented into multiple angled surfaces (first reflector surface, second reflector surface, third reflector surface) that are fixed at specific angles (e.g., 45 degrees) to each other. Each surface directs the laser beam to a specific portion of the workpiece (front, back, or lateral sides), eliminating the need for dynamic adjustment while maintaining precise beam positioning for consistent weld quality.
2Adaptability or versatility
If adjustable optical reflectors are used to cover all sides of workpiece, then adaptability to different welding positions is improved, but ease of operation deteriorates due to time-consuming angular and positional adjustments
Solution Approach 1:
The optical reflector is pre-configured with multiple surfaces fixed at specific angles (e.g., 45 degrees) to each other before operation. This preliminary arrangement ensures that the laser beam can reach all portions of the workpiece (front, back, and lateral sides) without requiring any angular or positional adjustments during setup, significantly reducing setup time while maintaining comprehensive coverage.
3Productivity
If laser beam is directed around entire circumference of workpiece, then productivity is improved through continuous welding, but measurement precision deteriorates due to difficulty in monitoring beam position around inaccessible areas
Solution Approach 1:
The fixed optical reflector acts as an intermediary that precisely redirects the laser beam around the workpiece circumference. The reflector's fixed angular surfaces (e.g., 45 degrees) ensure accurate beam positioning without requiring active monitoring or adjustment, allowing continuous high-speed welding while maintaining precise beam placement on inaccessible areas through the fixed geometric relationship between reflector surfaces and workpiece.
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, consistent welds with minimal setup time and effort, significantly increasing throughput by simplifying the setup process and reducing variability, while ensuring accurate coverage of the workpiece circumference without the need for complex adjustments.
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
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.