Laser Welding Resin Members Speed Feedback Control
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Solution Overview
Problem
Traditional laser welding methods for resin members with transmitting and absorptive properties face challenges in achieving dimensional accuracy and joining strength due to variance in approaching distance and excessive laser irradiation, leading to voids and thermal decomposition.
Innovation Solution
A method and apparatus that measure the approaching speed of resin members during laser irradiation and end the irradiation when a reduction in speed is detected, ensuring precise control and preventing excessive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser beam casting time is extended to ensure all resin members are butted against each other, then the dimensional accuracy is improved, but the joining strength at the welded part is reduced due to excessive heating
Solution Approach 1:
The control unit continuously monitors the approaching speed of the two resin members during laser irradiation and uses this feedback to dynamically adjust the irradiation time. When the approaching speed reduces to a predetermined threshold, indicating the members are about to butt against each other, the control unit automatically ends the laser irradiation. This feedback mechanism allows precise control of irradiation timing without requiring excessive extended time, thereby maintaining both dimensional accuracy and joining strength.
Solution Approach 2:
The system transitions from a static, fixed-duration laser irradiation process to a dynamic process where the irradiation time is continuously adjusted based on real-time approaching speed measurements. This dynamic adaptation allows the system to optimize irradiation duration for each individual welding operation, preventing both premature termination (which would compromise dimensional accuracy) and excessive continuation (which would reduce joining strength through thermal decomposition).
2Manufacturing precision
If the laser irradiation is ended based on predetermined approaching distance, then the dimensional accuracy is improved, but the variance in approaching distance remains due to control delay
Solution Approach 1:
Instead of relying on predetermined distance thresholds with inherent control delays, the system implements continuous feedback monitoring of the approaching speed. The control unit measures the actual approaching speed in real-time and compares it against a predetermined speed threshold. This speed-based feedback provides more responsive and reliable control, eliminating the variance caused by distance-based control delays while maintaining dimensional accuracy.
3Manufacturing precision
If the laser irradiation is continued after the resin members are butted against each other, then the dimensional accuracy is maintained, but the joining strength is reduced due to temperature rise causing voids and thermal decomposition
Solution Approach 1:
The system rapidly terminates the laser irradiation process the moment the approaching speed reduces to the predetermined threshold, effectively skipping any potential harmful continuation phase. This rapid decision and termination mechanism ensures that the laser irradiation does not continue into the region where thermal decomposition and void formation would occur, while still achieving the required dimensional accuracy through precise timing control.
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 secures dimensional accuracy and prevents reduction in joining strength by ending laser irradiation when the approaching speed decreases, thereby avoiding voids and thermal decomposition.
Implementation Method 1
The laser beam passes through the laser-transmitting resin almost without being absorbed at all and is absorbed in the vicinity of the surface of the laser-absorptive resin member
Implementation Method 2
The energy of the absorbed laser beam is converted to heat, which heats the surface of the laser-absorptive resin member
Implementation Method 3
the vicinity of the surface of the resin of the laser-transmitting member resin in contact with the surface of the laser-absorptive resin is heated by heat transfer
Data Source
AI summary
A welding method and welding apparatus for resin members is provided in which dimensional accuracy of two resin members after welding can be secured and reduction in joining strength due to excessive laser irradiation can be prevented. In a method of superimposing a resin having a laser-transmitting property and a resin having laser absorptiveness and irradiating the resin members with a laser beam from the side of the laser-transmitting resin member to deposit the resin members on each other, irradiation with the laser beam is ended in accordance with reduction in the approaching speed of the two resin members during the irradiation with the laser beam.