Vacuum Laser Welding Chamber With Movable Gap Covering
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Solution Overview
Problem
Existing laser welding technologies are unsuitable for welding large workpieces in a vacuum due to the need for large, hermetically sealed process chambers that require extensive space and complex vacuum maintenance, and mobile solutions suffer from leakage and pressure control issues.
Innovation Solution
A laser welding device with a gap-covering device that includes movable components and adjustable gap-covering elements to maintain a vacuum while welding large workpieces, allowing for stable, efficient welding of thick sheets and long weld seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stationary process chamber is used for laser welding in vacuum, then welding quality is improved, but the device cannot handle large workpieces and requires excessive space
Solution Approach 1:
The patent applies the dynamics principle by making the process chamber mobile rather than stationary. The process chamber can move along the workpiece to accommodate large dimensions, while the laser device remains relatively positioned. This dynamic configuration allows the system to handle large workpieces without requiring a proportionally large stationary chamber, resolving the contradiction between welding quality (maintained through vacuum) and adaptability to large workpieces.
2Adaptability or versatility
If the process chamber is made larger to accommodate large workpieces, then adaptability is improved, but vacuum maintenance becomes more complex and space requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the system into a mobile process chamber that can be positioned as needed, rather than requiring a single large stationary chamber. This allows the vacuum system to be confined to a smaller, manageable volume that can service large workpieces through movement, reducing vacuum maintenance complexity while maintaining adaptability.
Solution Approach 2:
The mobile process chamber enables the system to maintain a compact vacuum volume while handling large workpieces. By moving the chamber to different positions along the workpiece, the system avoids the need for a large stationary vacuum environment, thereby reducing vacuum maintenance complexity.
3Manufacturing precision
If a gap-covering device is added to maintain vacuum, then welding quality is improved, but device complexity increases
Solution Approach 1:
The patent merges the gap-covering function with the process chamber structure itself. The process chamber is designed to cover gaps between workpiece components as part of its sealing mechanism, rather than adding separate gap-covering devices. This integration maintains welding quality through effective gap sealing while minimizing additional structural 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
Enables efficient welding of large workpieces with reduced spatter and pore formation, minimizing energy consumption and maintaining weld quality, suitable for applications like offshore wind turbine monopiles.
Implementation Method 1
a laser beam generated by a laser device is focused into a small spot using focusing optics. Because the energy density of the laser light is very high, the material to be welded is quickly melted and partially vaporized
Implementation Method 2
a laser beam generated by a laser device is focused into a small spot using focusing optics
Implementation Method 3
Laser welding in a vacuum is a process modification of laser welding or laser beam welding. It combines the vacuum technology normally used in electron beam welding with the established joining technology of laser welding
Data Source
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AI summary
The present invention relates, inter alia, to a laser welding device (10) which is provided for welding workpieces (90, 91) under negative pressure, preferably in a vacuum, comprising a laser device (11) which is configured to generate and couple a processing laser beam (13) into a welding zone (17) of the laser welding device (10), comprising a first process chamber (30) which is provided in the beam direction (13a) of the processing laser beam (13), in particular in front of the welding zone (17), comprising a first process chamber closure (31) facing the laser device (11), a second process chamber closure (32) facing the welding zone (17), in which in particular an exit opening (32a) for the processing laser beam (13) into the welding zone (17) is formed, and a lateral third process chamber closure (33) extending between the first (31) and second (32) process chamber closures,wherein the laser device (11) is movable relative to the welding zone (17) in a defined welding direction (18). To enable laser welding under negative pressure, in particular in a vacuum, even for large workpieces, the laser welding device (10) is characterized in that at least one first gap-covering device (50) is provided, which is configured to cover a gap (92) between the workpieces (90, 91) to be welded and/or a gap (36) in the first process chamber (30), that the first gap-covering device (50) is provided above the welding zone (17), that the first gap-covering device (50) has a first gap-covering element (51) whose orientation with respect to the welding direction (18) is at least partially variable,that the first gap covering device (50) cooperates with the laser device (11) or the first process chamber (30) and that the first gap covering device (50) is provided in front of the laser device (11) or in front of the first process chamber (30) in the welding direction (18).