Pipe Fitting Laser Welding With Three-Stage Butt Joint Scanning
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Solution Overview
Problem
Existing manual welding of round pipe fittings results in uneven, non-uniform, and porous weld beads, leading to embrittlement, and is inefficient.
Innovation Solution
A laser welding method involving a laser assembly with rotating axes and a reflection assembly, performing multiple synchronized swinging motions to project and reflect laser beams across the butt joint of pipe fittings, dividing the weld zone into three procedures for consistent automated welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual welding is used for round pipe fittings, then flexibility and adaptability are maintained, but welding quality deteriorates with uneven, non-uniform, and porous weld beads
Solution Approach 1:
The welding process is segmented into multiple discrete steps (first welding step, second welding step, third welding step) with specific laser swinging angles for each step. This segmentation allows precise control of the welding process to achieve uniform weld beads while managing system complexity through structured procedure division
Solution Approach 2:
The laser assembly implements dynamic swinging motion with specific angles (first angle, second angle, third angle) relative to rotating axes during welding. This dynamic positioning enables the laser to trace complex paths around the pipe fitting, ensuring uniform weld quality while adapting to different welding positions
2Manufacturing precision
If automated laser welding is implemented, then welding quality and consistency are improved, but device complexity increases
Solution Approach 1:
The laser assembly is designed with multi-functionality, serving both as a welding source and a dynamically positioned tool through integrated swinging and rotating mechanisms. This universal design achieves consistent weld quality across different positions while consolidating functions to manage overall device complexity
Solution Approach 2:
The reflection assembly acts as an intermediary component that redirects the laser beam to access different welding positions on the pipe fitting. This intermediary mechanism enables complex welding paths without requiring the laser assembly to physically access all positions directly, simplifying the overall system architecture
3Productivity
If manual welding operations are performed, then adaptability to different pipe diameters is maintained, but productivity decreases due to time consumption
Solution Approach 1:
The laser assembly and reflection assembly are configured with rotating axes and dynamic swinging capabilities that automatically adapt to different pipe fitting diameters. This dynamic system maintains productivity by executing pre-programmed welding paths at optimized speeds while automatically adjusting to various diameter specifications
Solution Approach 2:
The system utilizes parameter changes in the laser swinging angles (first angle, second angle, third angle) and rotating axis positions to adapt to different pipe diameters. By modifying these parameters, the system maintains high welding speed and productivity across various fitting sizes without requiring manual reconfiguration
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
Enhances production efficiency and quality by reducing time consumption and ensuring uniform welds across different diameters, replacing labor-intensive manual processes with automated precision.
Implementation Method 1
the laser assembly to project a laser beam at the butt joint location of the two pipe fittings to be welded
Implementation Method 2
the laser assembly to perform welding while moving around the second rotating axis of rotation
Implementation Method 3
the laser beam projects to the reflection assembly and is reflected to the butt joint location of the other angle of the two pipe fittings to be welded
Data Source
AI summary
The present invention relates to a laser welding method of pipe fittings that mainly provides an automated butt welding process for two pipe fittings to be welded, comprising a laser welding device setup step, a material loading step, a first welding step, a second welding step, a third welding step, and a return to the original position step. The welding zone at the butt joint location of the two pipe fittings to be welded is divided to undergo three procedures through the aforementioned steps, using a laser assembly in conjunction with a reflection assembly, to provide a consistent automated butt welding for two pipe fittings to be welded.