Optical Sensor Fiber Feedback for Laser Welding Intensity Control
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Solution Overview
Problem
Conventional simultaneous laser welding technologies face challenges in accurately assessing and controlling the laser light intensity during the welding process, particularly in applications where there is limited space for sensors between the end of fiber bundles and the workpieces.
Innovation Solution
Incorporating a plurality of optical sensor fibers to sense the laser light output from laser delivery optical fibers and relay this information to a controller, allowing for real-time feedback and adjustment of laser intensity, either through positioning between the delivery end and the workpieces or integrated within the delivery bundles, with the option of forming an array and using a camera for detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensor fibers are positioned between the delivery end of laser delivery bundles and the workpieces, then laser light intensity can be sensed and feedback control is enabled, but the limited space available for sensors is exceeded
Solution Approach 1:
The patent combines the optical sensor fiber with the laser delivery bundle by incorporating the sensor fiber into the delivery bundle structure. This merging allows the sensor to be positioned within the limited space of the delivery bundle assembly, eliminating the need for separate sensor positioning space while still enabling laser light intensity sensing at the delivery end.
Solution Approach 2:
The optical sensor fiber is nested within the laser delivery bundle structure, with the sensor fiber positioned inside or along the delivery bundle. This nesting arrangement allows the sensor to occupy minimal additional space while maintaining its sensing function, effectively solving the space constraint problem.
2Reliability
If conventional laser welding technology is used, then the welding process is simple, but accurate assessment and control of laser light intensity during the welding process cannot be achieved
Solution Approach 1:
The patent implements a feedback control system where optical sensor fibers sense the laser light intensity at the delivery end, relay this information to a controller, and enable real-time adjustment of laser parameters. This feedback mechanism provides accurate assessment and control of laser light intensity during the welding process, significantly improving reliability.
Solution Approach 2:
The optical sensor fibers act as intermediaries between the laser delivery system and the control system. They transmit information about laser light intensity from the delivery end to the controller, enabling indirect measurement and control without disrupting the primary welding process.
3Productivity
If the gap between the delivery end of the fiber bundle and the waveguide is kept small to improve efficiency, then welding efficiency is improved, but space for sensor positioning is further reduced
Solution Approach 1:
By merging the optical sensor fiber with the laser delivery bundle, the sensor becomes an integrated part of the delivery system. This allows the sensor to be positioned within the minimal gap space between the fiber bundle delivery end and the waveguide, maintaining welding efficiency while enabling sensing functionality.
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 control and adjustment of laser light intensity, ensuring a satisfactory weld by providing immediate feedback and enabling automatic adjustments, thereby improving the efficiency and accuracy of the laser welding process.
Implementation Method 1
Optical fibers rely on the principle of total internal reflection to convey light from one end to the other.
Data Source
AI summary
Sensors comprising optical sensor fibers detect a laser light output from at least a laser delivery optical fiber to provide feedback of the laser light intensity detected by the optical sensor fiber. The optical sensor fibers may be integrated within a laser delivery bundle, or may be positioned between a delivery end of the laser delivery optical fiber and a plurality of work pieces to be welded. In various aspects, the feedback provided from the optical sensor fibers is used to control the laser light intensity or to alert an operator that the laser light intensity has fallen below a predetermined parameter.