Remote Laser Welding Coated Sheets with Scanner Feedback
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Solution Overview
Problem
Existing laser remote welding methods for coated sheets face issues such as gaps between sheets, coating vapor condensation leading to spacing, and deviations from desired weld courses due to component tolerances, which can result in poor degassing conditions and increased process disturbances.
Innovation Solution
A method utilizing a scanner device to guide a laser beam for producing an end fillet weld on a lap joint, with continuous weld production recording and automatic evaluation of images to correct the laser beam path, ensuring precise alignment and zero-gap welding without filler metals, and allowing for online regulation of the weld course.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is used for remote welding of coated sheets, then welding speed is improved, but deviations from desired weld course occur due to component tolerances
Solution Approach 1:
The patent implements an imaging unit that continuously records the weld course during laser remote welding. The control unit evaluates these images and automatically corrects the laser beam path by adjusting the scanner device. This closed-loop feedback system compensates for component tolerances and maintains precise weld alignment while preserving high welding speeds enabled by laser remote processing.
Solution Approach 2:
The patent employs dynamic correction of the weld course by continuously monitoring the welding process with an imaging unit and adjusting the laser beam path in real-time through the scanner device. This dynamic adaptation allows the system to maintain manufacturing precision despite variations in component positions, while the laser remote welding technique itself provides high productivity through rapid processing speeds.
2Manufacturing precision
If coating vaporization is performed before welding, then coating removal is improved, but gaps and spacing occur between sheets due to vapor condensation
Solution Approach 1:
The patent performs preliminary vaporization of the coating material using the laser beam before the welding process begins. This preliminary action removes the coating that would otherwise interfere with welding, while the system is designed to prevent vapor condensation between sheets through controlled processing parameters and timing, thus avoiding gap formation.
Solution Approach 2:
The patent combines coating vaporization and welding into a continuous laser beam process. The laser beam continuously acts on the material, first vaporizing the coating and then immediately welding the sheets together without interruption. This continuous action prevents vapor condensation between sheets by rapidly transitioning from vaporization to welding, maintaining sheet contact and avoiding gap formation while ensuring complete coating removal.
3Manufacturing precision
If manual weld course correction is used, then alignment accuracy is improved, but process complexity and time consumption increase
Solution Approach 1:
The patent replaces manual mechanical adjustment methods with an automated optical-mechanical system. An imaging unit captures weld course deviations, a control unit processes the image data to determine corrections, and a scanner device automatically adjusts the laser beam path. This substitution of manual operations with automated systems maintains high alignment accuracy while reducing process complexity and eliminating time-consuming manual interventions.
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 enables robust, high-speed laser remote welding with improved degassing conditions, reduced process disturbances, and automated quality inspection, suitable for serial production in vehicle body construction by maintaining precise weld alignment and eliminating gaps between sheets.
Implementation Method 1
the sheet facing the laser beam is first heated by the laser beam, wherein the coating of both sheets vaporizes on their mutually facing sides
Implementation Method 2
the laser beam is deflected by at least one movable rotating mirror or scanner mirror, and is positioned and guided onto the sheets to be joined
Data Source
AI summary
A method is provided for the remote laser welding of two coated sheets, wherein by way of a scanner, a laser beam is directed at the sheets to be connected to each other and guided on the sheets. The sheets are connected to each other by producing an end fillet weld on a lap joint. The continuous production of the weld is recorded by a camera and, if necessary, the path of the laser beam is corrected and adapted to a target weld course on the basis of an automatic evaluation of the recorded images.