Rotary Weld Toolpath Correction for 3D Gap Alignment
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Solution Overview
Problem
Current laser beam welding technologies face limitations in achieving precise alignment of the laser beam with complex three-dimensional workpieces, as existing vision-based seam tracker systems can only correct for vertical and lateral translations, failing to maintain the laser beam's normality to the gap between parts with complex geometries.
Innovation Solution
A vision-based rotary part offset sensing method that uses a machine vision camera to detect deviations between the preprogrammed laser toolpath and the gap centerpoint, allowing for real-time corrections by rotating the rotatable fixture and adjusting the laser unit's position to align the laser beam with the gap centerpoint, incorporating a motion system with a rotary axis and three linear axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vision-based seam tracker systems are used for real-time toolpath correction, then vertical and lateral translation corrections are improved, but the laser beam normality to the gap is not maintained for complex three-dimensional geometries
Solution Approach 1:
The invention introduces rotary axis corrections in addition to the existing vertical and lateral translation corrections. By adding rotational degree of freedom to the correction mechanism, the system can now handle complex three-dimensional geometries and maintain laser beam normality to the gap, resolving the limitation of previous two-dimensional correction systems.
2Extent of automation
If the laser unit follows a preprogrammed toolpath for complex three-dimensional workpieces, then welding automation is improved, but alignment precision with the gap centerpoint deteriorates due to workpiece form variations
Solution Approach 1:
The system uses vision-based detection to continuously monitor the actual gap centerpoint position and compares it with the preprogrammed toolpath. Real-time feedback is provided to the correction system, which then adjusts the laser unit position and orientation to compensate for workpiece form variations, maintaining precise alignment throughout the automated welding process.
Solution Approach 2:
The correction system dynamically adjusts the laser unit's position and orientation during the welding process. Instead of following a fixed preprogrammed path rigidly, the system adapts the toolpath in real-time based on actual workpiece geometry detected by the vision system, enabling precise welding of complex three-dimensional shapes with varying forms and dimensions.
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 significantly enhances the precision of laser weld processing by enabling pointwise corrections, ensuring the laser beam remains normal to the gap, thereby improving the welding of complex three-dimensional shapes with reduced thermal damage.
Implementation Method 1
A vision-based seam tracker system is currently available for real-time toolpath correction during laser beam welding
Implementation Method 2
Laser beam welding uses a highly focused laser beam for joining two parts. The laser beam provides a concentrated heat source
Implementation Method 3
The first and second parts are secured to a rotatable fixture, and the rotatable fixture rotates through a corrective angle to bring the gap centerpoint into alignment with the laser beam toolpath
Data Source
AI summary
An improved laser weld process control system and method are provided. The system and method include a machine vision camera to detect a deviation between a pre-programmed laser beam toolpath and a gap centerpoint between first and second parts being welded together. The first and second parts are secured to a rotatable fixture, and the system and method cause the rotatable fixture to rotate through a corrective angle to bring the gap centerpoint into alignment with the laser beam toolpath, optionally in real time during the application of laser beam energy. The system and method can also correct for a vertical misalignment of the laser focal point due to rotation of the fixture by adjusting the vertical separation of the laser unit relative to the fixture.