Spatter Cooling Device for Laser Welder Discharge
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Solution Overview
Problem
Laser welding processes face issues with spatter accumulation in the welding chamber, leading to contamination and reduced welding quality, as conventional systems fail to effectively remove and cool spatter generated during the process.
Innovation Solution
A spatter removing device for laser welders, comprising an optic head, cross jet, safety cover, material injection unit, discharge unit with a spatter cooling device, and a collection unit, which uses a spatter cooling device with a gas injection hole and nozzle to cool and collect spatter using inert gases, preventing re-deposition and maintaining chamber cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spatter is discharged directly without cooling, then the discharge process is simple, but the spatter causes contamination and welding quality degradation
Solution Approach 1:
A cooling device is introduced as an intermediary component between the spatter discharge pipe and the welding chamber. This cooling device cools the spatter before it is discharged, preventing contamination while maintaining a relatively simple overall system structure. The cooling device acts as a mediator that transforms hot spatter into cooled spatter that can be safely removed.
Solution Approach 2:
The harmful thermal property of spatter is extracted and addressed separately through a dedicated cooling mechanism. By extracting the cooling function as a separate component rather than trying to solve contamination through complex filtration or containment systems, the solution achieves welding quality improvement without excessive system complexity.
2Manufacturing precision
If cooling gas is injected to cool spatter, then spatter collection efficiency is improved, but energy consumption increases
Solution Approach 1:
The system uses pneumatic principles by injecting cooling gas through nozzles to cool and collect spatter. The cooling gas flow is utilized to carry cooled spatter out of the welding chamber through the discharge pipe. This pneumatic approach achieves efficient spatter collection without requiring complex mechanical collection mechanisms, balancing effectiveness with energy efficiency.
3Reliability
If spatter is not cooled before discharge, then the discharge process is straightforward, but spatter causes material failure
Solution Approach 1:
The spatter is cooled before discharge through the cooling device, which is a preliminary action taken before the spatter leaves the welding chamber. By cooling the spatter in advance, the system prevents material failure and contamination issues that would occur if hot spatter were discharged directly. This preliminary cooling action ensures material reliability while keeping the discharge mechanism itself relatively simple.
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
The device effectively cools, collects, and removes spatter, preventing material failure and maintaining a clean welding environment, thereby enhancing welding quality and productivity.
Implementation Method 1
a spatter cooling device cooling the spatter so that the spatter is forcibly collected
Implementation Method 2
The spatter cooling device may be provided with a gas injection hole formed in an outer circumferential surface thereof, a nozzle formed in an inner circumferential surface thereof to spray a cooling gas injected from the gas injection hole
Data Source
AI summary
A spatter removing device for a laser welder including an optic head to which a laser beam is transferred through an optic fiber from a laser oscillator, a cross jet mounted at one side of a lower end portion of the optic head, a safety cover provided at the outside of the optic head so as to surround the optic head, and a material injection unit that injects a material to be welded below the optic head, the device includes a discharge unit and a spatter cooling device. The discharge unit is provided with a discharge pipe that discharges a welding gas and the spatter at one side portion of the safety cover. The spatter cooling device is connected to the discharge pipe and cools the spatter so that the spatter is forcibly collected.