Offset Dual Laser Welding Heads for Strip Edge Alignment
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Solution Overview
Problem
Existing continuous welding systems face challenges such as dirt accumulation, laser radiation passing through narrow gaps, and edge misalignment during the welding of thin metal sheets, leading to inefficient welding processes and the need for manual cleaning and precise control of laser power.
Innovation Solution
A device with at least two offset welding heads arranged on both sides of the strips or sheets, where the energy beams' points of impact are spaced apart by at least half the outer diameter of the tensioning roller, allowing for separate and optimized welding processes with adjustable energy beam powers to prevent dirt accumulation and ensure uniform welds, and a spoked wheel tensioning roller design for improved thermal stability and edge alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single welding head is provided in one of the tensioning rollers, then the device complexity is reduced, but the welding speed and productivity are limited
Solution Approach 1:
The patent combines multiple welding heads (at least two) into a single continuous welding system, allowing simultaneous welding operations on multiple sheets or strips. This merging of welding functions increases productivity while maintaining manageable device complexity through integrated design.
Solution Approach 2:
The patent introduces a temporal dimension to the welding process by offsetting the welding heads in the running direction of the sheets. This dimensional arrangement allows continuous welding operations without interruption, transforming the process from sequential to continuous, thereby increasing productivity.
2Strength
If laser power is increased to weld thicker sheets, then the welding capability is improved, but dirt accumulation on the panel increases
Solution Approach 1:
The patent extracts the harmful effect (dirt accumulation) by introducing a second welding head positioned on the opposite side of the sheet. This second head removes contaminants that accumulate on the surface during welding of thicker sheets, allowing higher laser power to be used without excessive dirt buildup.
Solution Approach 2:
The patent converts the harmful laser radiation that would otherwise pass through narrow gaps and cause dirt accumulation into a beneficial welding action by positioning the second welding head to utilize this radiation for welding the opposite side of the sheet, thereby eliminating the harmful effect.
3Manufacturing precision
If an opposite second welding head is arranged to weld through narrow gaps, then the welding uniformity is improved, but the welding head is exposed to constant laser beam bombardment
Solution Approach 1:
The patent positions the second welding head in a different spatial location (offset in the running direction and on the opposite side of the sheet) rather than directly opposite the first head. This dimensional arrangement allows the welding head to receive laser radiation for welding without direct exposure to laser beams passing through narrow gaps.
Solution Approach 2:
The patent introduces the metal sheet itself as an intermediary that blocks and directs the laser beams. The sheet material prevents laser radiation from directly bombarding the second welding head while still allowing the welding process to proceed uniformly on both sides of the sheet.
4Productivity
If welding speed is increased for thin sheets, then the productivity is improved, but the weld seam uniformity and smoothness deteriorate
Solution Approach 1:
The patent combines the welding actions of two welding heads operating simultaneously on opposite sides of thin sheets. This merged welding process maintains weld seam uniformity and smoothness even at high welding speeds by providing balanced thermal input from both sides, preventing distortion that would occur with single-sided welding.
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 configuration enables high-speed, uniform, and smooth weld seams on thin sheets, doubling welding speeds compared to conventional systems, while reducing thermal stress and edge misalignment, and allowing for easier optimization of process parameters.
Implementation Method 1
the longitudinal edges of the strip to be welded are welded with the aid of at least one laser beam (20, 28) acting from above and/or from below
Implementation Method 2
the metal components in the weld seam area are melted from both sides with the aid of at least one welding beam, in particular a laser beam, in heat conduction mode over essentially the entire weld seam cross-section
Implementation Method 3
the metal components in the weld seam area are melted from both sides with the aid of at least one welding beam, in particular a laser beam
Data Source
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AI summary
The invention relates to a method and corresponding device for continuously welding strips or sheets (3, 4) guided by abutment at the abutting edges thereof, having at least two welding heads (19, 25), in particular laser welding heads, and tensioning rollers (5, 6) disposed on both sides of the strips or sheets (3, 4) to be welded and perpendicular in pairs to the running direction thereof, forming a gap in the region of the abutment (24) of the strips or sheets (3, 4), through which an energy beam emitted by a first (19) of the at least two welding heads impinges on the strip or longitudinal edges to be welded, wherein a second (25) of the at least two welding heads is disposed on the opposite side of the strips or sheets (3, 4), the energy beam thereof impinging on said opposite side on the strip or longitudinal edges to be welded, wherein the at least two welding heads (19, 25) are disposed offset to one another in the direction of flow of the strips or sheets (3, 4), so that the impinging points (26, 27) of the energy beams on the strip or longitudinal edges to be welded are spaced apart from each other by at least half of the outer diameter of the tensioning roller (6) facing the first energy beam.