Tubular Hold-Down Tool Insert for Tolerance-Safe Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Classic laser welding systems are limited in their ability to compensate for shape and position tolerances of contact components, leading to potential mechanical damage, contamination, and non-directional reflection of laser beams, especially when welding sensitive electronic components.
Innovation Solution
A hold-down tool with a tubular hollow body and a flexibly attached tool insert that compensates for shape and position tolerances, shields the laser beam, and prevents contamination, featuring a spring-mounted design and interchangeable parts for durability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid hold-down tool is used to press contact components, then welding precision can be maintained, but mechanical damage to sensitive electronic components occurs due to inability to compensate for shape and position tolerances
Solution Approach 1:
The patent employs a flexible tool insert made of elastomeric material that can deform to accommodate shape and position tolerances of contact components. This flexible element presses the components together while adapting to their geometric variations, preventing mechanical damage to sensitive electronic components while maintaining sufficient contact pressure for welding.
Solution Approach 2:
The patent utilizes the elastic properties of the tool insert material, characterized by appropriate hardness and elasticity parameters. The elastomeric material's ability to deform elastically under load allows it to compensate for component tolerances while maintaining consistent contact force, resolving the contradiction between precision and mechanical stress.
2Productivity
If the laser beam is directed at contact components without shielding, then welding can be performed, but non-directional reflection of the laser beam creates safety hazards
Solution Approach 1:
The patent introduces a laser-absorbing coating on the tool insert as an intermediary element. This coating absorbs the laser beam energy that would otherwise reflect directionlessly, converting it to thermal energy that assists in the welding process. The tool insert with coated surface acts as a mediator between the laser source and the contact components, eliminating the safety hazard while maintaining welding productivity.
3Productivity
If traditional laser welding systems are used, then welding can be performed, but shape and position tolerances of contact components cannot be adequately compensated
Solution Approach 1:
The flexible elastomeric tool insert deforms to accommodate geometric variations in contact components, enabling the system to handle components with shape and position tolerances while maintaining consistent welding quality and productivity.
Solution Approach 2:
The tool insert transitions from a rigid structure to a dynamic, deformable element that adapts its shape during the welding process. This dynamic behavior allows real-time compensation for component tolerances, improving both precision and productivity simultaneously.
4Manufacturing precision
If a spring-mounted tool insert is used to provide flexibility, then tolerance compensation is achieved, but device complexity increases
Solution Approach 1:
The elastomeric tool insert provides the necessary flexibility and tolerance compensation through its material properties alone, eliminating the need for complex spring mechanisms or articulated joints. The simple, monolithic elastomeric structure achieves the desired compliance while minimizing device complexity.
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
Ensures secure and error-free welding by compensating for component tolerances, reducing mechanical stress, and preventing contamination and laser beam reflection, while maintaining robustness and cost-effectiveness.
Implementation Method 1
A pressure spring can be provided for spring-mounted support of the tool insert on the hollow body
Implementation Method 2
the laser beam for welding the contact components can be guided through the tubular hollow body to a connection point
Implementation Method 3
the hold-down tool with the tool insert can at the same time compensate for the shape and position tolerances of the contact components to be welded
Data Source
AI summary
A hold-down tool for a laser welding system. A tubular hollow body has a lateral surface that is designed to be closed in a laminar manner at least in some sections. A tool insert is formed as a contact element which is flexibly held on the hollow body and provides a tool contact surface for bringing the tool insert into contact with a first contact component to be welded.