Multi-Faceted Optical Reflector for 360° Circumferential Laser Welding
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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 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 tubular workpiece, allowing only vertical adjustment of the workpiece relative to the reflector, eliminating the need for rotational adjustments and reducing setup time while ensuring consistent weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single, fixed optical reflector with multiple angled surfaces is used to direct the laser beam around the workpiece, then weld consistency and quality are improved, but the ability to reach inaccessible areas of the workpiece deteriorates
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 relative to each other. Each surface is responsible for directing the laser beam to specific areas of the workpiece, with the first surface handling front areas, the second surface handling lateral areas, and the third surface handling bottom areas, thus achieving both consistency and accessibility
Solution Approach 2:
The patent transitions from a two-dimensional planar reflector to a three-dimensional multi-faceted optical reflector with surfaces angled in different spatial dimensions. This allows the laser beam to be redirected to areas that would otherwise be inaccessible from a single fixed position, including lateral and bottom areas of the workpiece
2Adaptability or versatility
If complex optical systems with multiple adjustable reflectors are used, then accessibility to all workpiece areas is improved, but device complexity and setup time increase
Solution Approach 1:
Multiple reflector functions are merged into a single integrated optical reflector assembly. The first, second, and third reflector surfaces are fixed at predetermined angles to each other, eliminating the need for separate adjustable reflectors and reducing system complexity while maintaining comprehensive workpiece coverage
Solution Approach 2:
The single optical reflector assembly performs multiple functions simultaneously: it directs the laser beam to front areas, lateral areas, and bottom areas of the workpiece through its multiple angled surfaces, replacing what would traditionally require multiple separate reflector systems
3Manufacturing precision
If adjustable optical reflectors are used to cover all sides of the workpiece, then weld coverage is improved, but setup time and adjustment complexity increase
Solution Approach 1:
The optical reflector surfaces are pre-configured at fixed angles during manufacturing (first surface at 45° to laser beam, second surface at 45° to first surface, third surface at 45° to second surface). This preliminary action eliminates the need for time-consuming adjustments during setup, as the geometry is predetermined to achieve complete workpiece coverage
4Manufacturing precision
If the laser source is rotated around the workpiece or the assembly is spun, then 360° circumferential weld is achieved, but manufacturing complexity and production efficiency deteriorate
Solution Approach 1:
Instead of rotating the laser source or workpiece to achieve 360° coverage, the patent inverts the approach by using a stationary laser source with a multi-faceted optical reflector that redirects the beam around the workpiece. This eliminates mechanical rotation while achieving complete circumferential 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 approach results in high-quality, consistent 360° circumferential welds with minimal setup time and effort, increasing throughput by simplifying the setup process and eliminating the need for iterative adjustments, thus improving weld quality and efficiency 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
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.