Remote Laser Welding Control via Pressure-Sensing Stylus
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Solution Overview
Problem
High-power lasers used in surface processing, such as welding, pose a significant safety risk to operators due to the need for direct monitoring of the processing area, making it hazardous and potentially fatal.
Innovation Solution
A control element, such as a stylus with position and pressure sensors, is used to control a welding robot remotely, allowing the operator to guide the laser from a safe distance and precision-manage the welding process through image recognition and feedback, enabling precise control without direct exposure to the laser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator directly monitors the processing area during laser welding, then welding precision is improved, but operator safety deteriorates due to exposure to high-power laser radiation
Solution Approach 1:
The patent introduces an intermediary system consisting of a camera and display device between the operator and the laser processing area. The camera captures real-time images of the workpiece and welding area, transmitting them to a display device that the operator can view remotely. This intermediary setup allows the operator to monitor the welding process with high precision without being exposed to harmful laser radiation, thus resolving the contradiction between welding precision and operator safety.
2Measurement precision
If the operator uses a microscope to observe the workpiece region, then observation precision is improved, but the operator must remain by the laser processing apparatus which increases safety risk
Solution Approach 1:
The patent transitions the observation system from a spatial dimension problem to a different dimensional solution by using a camera-based imaging system that can be positioned remotely. Instead of requiring the operator to physically position themselves near the laser apparatus with a microscope, the camera captures images that can be displayed on a screen anywhere in the workspace. This dimensional shift allows high-resolution observation without compromising operator safety or ease of operation.
3Adaptability or versatility
If a welding robot is not mounted in a fixed position, then flexibility in welding operations is improved, but the zero position of the robot becomes unknown which reduces positioning accuracy
Solution Approach 1:
The patent employs image recognition technology that creates a digital copy or representation of the workpiece and its features. By capturing images of the workpiece and using recognition algorithms to identify key features and positions, the system establishes the robot's zero position and coordinates without requiring fixed mounting. This copying approach allows the robot to operate flexibly at various positions while maintaining positioning accuracy through visual reference to the workpiece features.
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 solution significantly reduces the risk of injury to the operator by allowing remote control of the welding process, ensuring precise operation and safety while maintaining high precision in welding tasks, even when the welding robot is not fixed in position.
Implementation Method 1
a sensor for its position
Implementation Method 2
a pressure sensor
Implementation Method 3
use has to be made of a laser having a power of greater than 1 kW
Implementation Method 4
a welding wire whose material is transferred, after melting, into the location that is to be repaired
Data Source
AI summary
In a method for processing a workpiece (2) using a tool (9), in particular for repairing a surface (4) using a laser, the tool (9) being piloted by a control element (10), the tool (9) is to be controlled via a position of the control element (10) and a pressure which is applied either to the control element (10) or by the control element (10).