Square Pipe Laser Welding Through Opposing Through-Holes
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Solution Overview
Problem
In the manufacturing of image forming apparatus structures involving bonded square pipes, there are challenges in welding specific members to the pipes due to restrictions on the position and direction of laser light scanning, making it difficult to achieve a strong bond, especially when the laser light cannot be easily radiated onto the boundary between the pipe and the member.
Innovation Solution
A manufacturing method that involves forming through-holes in the pipes and members, using positioning jigs to align them, and performing a first temporary weld through a second through-hole to facilitate orientation changes for a subsequent solid weld, allowing for bonding even under scanning restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is performed directly on the boundary between the pipe and member, then strong bonding is achieved, but the laser light cannot be radiated due to scanning position and direction restrictions
Solution Approach 1:
The method performs a preliminary temporary weld at a different position (first position) before the final welding operation. This preliminary weld enables subsequent orientation changes of the workpiece to achieve proper scanning conditions for the solid weld, resolving the contradiction by preparing the workpiece in advance for the actual bonding operation.
Solution Approach 2:
The temporary weld acts as an intermediary step that facilitates the transition from inaccessible to accessible welding positions. By creating this intermediate bonding, the workpiece can be reoriented and held in positions that allow proper laser scanning for the final solid weld.
2Ease of manufacture
If the workpiece orientation is changed to enable laser scanning, then welding accessibility is improved, but the bonding strength may be compromised without preliminary positioning
Solution Approach 1:
The temporary weld is performed first to establish a preliminary bond, and only after this preliminary bonding is the workpiece orientation changed. This sequence ensures that the workpiece can be repositioned without compromising the final bonding strength, as the repositioning occurs after the preliminary anchor is in place.
Solution Approach 2:
The welding process is divided into two distinct stages: a temporary weld stage for positioning and accessibility, and a solid weld stage for final bonding strength. This segmentation allows each stage to optimize for its specific purpose without compromising the other.
3Ease of manufacture
If temporary welding is performed first to enable orientation changes, then welding accessibility is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The welding process is divided into two distinct stages: a temporary weld stage for positioning and accessibility, and a solid weld stage for final bonding strength. This segmentation allows each stage to optimize for its specific purpose without compromising the other.
Solution Approach 2:
The temporary weld serves a specific function (enabling repositioning) and is then replaced by the final solid weld. The temporary bonding is effectively discarded once its positioning purpose is fulfilled, and the final strong bond is established in its place.
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
Enables effective welding of square pipes and sheet-metal members under restricted scanning conditions, ensuring a strong and reliable bond, which is crucial for maintaining the structural integrity of the image forming apparatus.
Implementation Method 1
radiating laser light of a laser welder onto a first bonding region including a boundary between an edge portion of the first through-hole on the target side wall and the specific member
Data Source
AI summary
A first through-hole is formed on a target side wall in a specific pipe of a structure, and a second through-hole is formed on an opposing side wall which opposes the target side wall. A manufacturing method of the structure includes arranging a specific member along an outer surface of the target side wall. The manufacturing method further includes radiating laser light of a laser welder onto a first bonding region via the second through-hole on the opposing side wall, to weld the specific pipe and the specific member in the first bonding region. The first bonding region includes a boundary between an edge portion of the first through-hole on the target side wall and the specific member.