Spot Weld Center Detection for Precise Laser Weld Alignment
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Solution Overview
Problem
In manufacturing vehicles, the combination of spot welding and laser welding often results in irregular positional relationships between the two processes, leading to potential welding quality issues due to excessive plate gaps or misalignment, which is not accurately addressed by existing methods.
Innovation Solution
A method to detect the center coordinates of a spot welding mark using linear laser light emission, waveform analysis of return light, and calculation of edge positions to accurately adjust the laser welding position, ensuring precise alignment and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spot welding and laser welding are performed using different equipment in mass production, then productivity is improved, but manufacturing precision deteriorates due to irregular positional relationships between welding marks
Solution Approach 1:
The patent implements a feedback mechanism by detecting the actual position of the spot welding mark and using this information to adjust the laser welding position. The center coordinate detection system provides real-time feedback about welding mark position, enabling dynamic correction of laser irradiation position to maintain precise alignment despite variations from different welding equipment
Solution Approach 2:
The patent replaces mechanical positioning methods with optical detection and computational coordinate calculation. Instead of relying on mechanical fixtures or manual positioning, the system uses laser light emission, return light detection, and mathematical algorithms to determine center coordinates and adjust welding positions, achieving higher precision without mechanical complexity
2Ease of operation
If laser welding is performed without accurate center coordinate detection, then ease of operation is improved, but manufacturing precision deteriorates due to incorrect laser welding position
Solution Approach 1:
The system performs self-positioning by automatically detecting the spot welding mark center coordinates and calculating the appropriate laser welding position. The automated coordinate detection and calculation eliminate the need for manual positioning operations, maintaining ease of operation while achieving high precision through self-correction
Solution Approach 2:
The patent performs preliminary detection of the spot welding mark position before executing laser welding. By detecting center coordinates in advance and calculating the optimal laser welding position beforehand, the system ensures precise positioning without requiring complex real-time adjustments during the welding operation
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 method enables accurate detection of spot welding mark centers, allowing for improved welding quality by maintaining the correct positional relationship between spot and laser welding, reducing defects, and ensuring appropriate melting of metal surfaces.
Implementation Method 1
a waveform acquiring step of acquiring a waveform of an intensity of return light which is light generated from a processing point by emitting the laser light
Implementation Method 2
a linear laser light emitting step of emitting a plurality of linear laser light components with a linear irradiation trace on a spot welding mark by emitting laser light through continuous output oscillation
Data Source
AI summary
A method of detecting center coordinates of a spot welding mark includes: a linear laser light emitting step of emitting a plurality of linear laser light components with a linear irradiation trace on a spot welding mark by emitting laser light through continuous output oscillation; a waveform acquiring step of acquiring a waveform of an intensity of return light which is light generated from a processing point; an outer edge position coordinates deriving step of deriving position coordinates of three or more points on an outer edge of the spot welding mark from a peak position of the intensity of the waveform of the return light; and a center coordinates calculating step of calculating center coordinates of the spot welding mark from the position coordinates of the three or more points on the outer edge derived in the outer edge position coordinates deriving step.