Multi-Fiber Laser System for Welding Without Scanners
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Solution Overview
Problem
Existing multi-beam laser systems for materials processing are costly and complex, requiring sophisticated optics and mechanical scanners for precise spot and seam welding, which are not optimized for demanding industrial applications like spot welding and seam welding with wobble configurations.
Innovation Solution
A laser system with multiple independently controlled fiber laser outputs, fused to a bulk optic, providing incoherent laser beams in a circumferential arrangement, allowing for sequential activation of multiple beams to create spot or seam welds without the need for mechanical scanners, using a low-cost and robust optic configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple laser outputs are combined using mirrors and fiber optic cables as in US Patent No. 5,048,911, then parallel outputs can be delivered, but the system requires multiple optics that introduce complexity and increase cost
Solution Approach 1:
The patent combines multiple laser outputs (at least three) into a single fiber optic cable using a fusion splicing approach, eliminating the need for multiple separate optics and mirrors. This merging of optical paths reduces system complexity and eliminates alignment issues associated with multiple optical components while maintaining reliable output delivery.
Solution Approach 2:
The patent replaces mechanical optical alignment systems (mirrors, lenses, and registration guides) with a fusion splicing technique that permanently joins fiber optic cables at the microscopic level. This substitution eliminates mechanical alignment complexity and improves reliability by creating a stable, degradation-free connection.
2Adaptability or versatility
If fiber laser outputs are combined using multiple couplers and lenses in a cascade approach as in US Patent No. 6,229,940, then incoherent laser light outputs can be produced, but the system is limited to single mode light only
Solution Approach 1:
The patent creates a universal coupling system that handles both single-mode and multi-mode laser outputs through the same fusion splicing technique. This universal approach eliminates the need for different coupling mechanisms for different light modes, thereby increasing adaptability while actually reducing device complexity compared to mode-specific systems.
3Manufacturing precision
If aligned fiber optical arrangements are used as in US 2004/0081396, then beam collimation can be achieved, but registration guides are required to align fibers and downstream optics
Solution Approach 1:
The patent replaces mechanical registration guides and alignment systems with fusion splicing technology. The fusion splicing process inherently aligns fiber cores at the microscopic level through precise positioning and melting, eliminating the need for external registration guides while achieving superior alignment precision and beam collimation.
4Manufacturing precision
If expensive scanners are used for laser spot welding and seam welding with wobble configurations, then precise welding can be achieved, but the system cost and complexity increase significantly
Solution Approach 1:
The patent segments the welding function into multiple independent laser outputs (at least three) that can be independently controlled and directed at different locations. This segmentation eliminates the need for a single scanner to move a beam across the workpiece, as multiple stationary beams can simultaneously target different spots, thereby reducing scanner complexity and cost while maintaining welding precision.
Solution Approach 2:
The patent employs periodic activation of multiple laser outputs in a sequential pattern to achieve welding effects previously requiring continuous scanner movement. By activating lasers in a controlled sequence (periodic action), the system can create spot welds and wobble seam welds without mechanical scanners, reducing system complexity while maintaining precision.
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
Enables precise and reliable spot and seam welding with reduced costs and complexity, eliminating the need for expensive scanners and allowing for downsizing of welding equipment, while providing consistent weld quality across various materials like aluminum and steel alloys.
Implementation Method 1
the respective fibers for the multiple beam outputs are fused to a bulk optic adjacent to the telminal end of a processing fiber
Implementation Method 2
each distinct fiber laser output configured to deliver an amount of energy sufficient to contribute to a pattern of material interaction
Implementation Method 3
A laser system with multiple independently controlled fiber laser outputs... providing incoherent laser beams... allowing for sequential activation of multiple beams to create spot or seam welds
Data Source
Figure 1
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Figure 3a~3b
AI summary
The present invention provides a multi-fiber laser output system that delivers at least three fiber outputs arranged in a circumferential pattern or otherwise at least four distinct laser outputs from a single processing cable. The present invention allows for controlling the at least three laser modules and delivering their respective outputs in a pre-determined sequence in a single processing cable, thereby providing multiple processing steps on a work piece that heretofore required separate optics for each beam. The at least three laser outputs are optimized for use in creating spot welds, seam welds or virtual wobble welds when used for seam welding.