Vacuum Laser Welding with Rotating Goggles
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Solution Overview
Problem
Existing laser welding methods for metal workpieces face challenges in achieving high-quality welds with short non-productive times, as they often require complex vacuum setups and are prone to contamination and oxidation, especially when using electron beam welding which is expensive and sensitive to air ingress.
Innovation Solution
A method and system for vacuum laser welding where the workpiece, workpiece carrier, and welding goggles are moved relative to each other to create a sealed chamber, allowing for rapid evacuation and rotation during laser processing, minimizing space and reducing contamination by using a compact welding chamber design with rotating welding goggles and controlled gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large vacuum chamber is used for electron beam welding, then welding precision is improved, but evacuation time increases significantly
Solution Approach 1:
The welding chamber is segmented into a compact configuration where the workpiece carrier, welding goggles, and housing work together to create a sealed volume only around the welding area. This segmentation allows the vacuum chamber to be much smaller than traditional electron beam welding chambers while maintaining welding precision.
Solution Approach 2:
The welding goggles are extracted as a separate, movable component that can be positioned close to the workpiece to define the vacuum chamber boundaries. This extraction allows the vacuum chamber to be formed dynamically around the welding area rather than requiring a large fixed chamber.
2Manufacturing precision
If electron beam welding is used, then welding precision is improved, but device cost and fragility increase
Solution Approach 1:
The invention replaces the expensive and fragile electron gun with a more robust and inexpensive laser beam source. The laser can tolerate air ingress better and is less costly, while the compact vacuum chamber design maintains welding quality.
Solution Approach 2:
The mechanical electron beam generation system is replaced with an optical laser system. The laser beam achieves similar welding precision without requiring the complex electron gun assembly, vacuum seals, and associated mechanical components.
3Volume of stationary object
If the workpiece is moved close to the welding goggles to seal the chamber, then chamber volume is reduced, but sealing complexity increases
Solution Approach 1:
The sealing requirement is applied locally at the interface between the workpiece carrier and welding goggles rather than requiring a complete seal around the entire chamber. The first and second seals are positioned specifically where the workpiece carrier contacts the welding goggles, simplifying the sealing system.
Solution Approach 2:
The welding goggles are made rotatable on the workpiece carrier, allowing dynamic adjustment of the sealing interface. This rotational capability maintains seal integrity while accommodating positioning variations and enabling the workpiece to define the chamber boundaries.
4Device complexity
If the welding goggles are fixed, then sealing is simpler, but rotation during welding becomes difficult
Solution Approach 1:
The welding goggles are made rotatable on the workpiece carrier through a bearing connection, allowing the workpiece and welding goggles to rotate together during laser processing. This dynamic design maintains simple sealing at the fixed interface while enabling necessary rotation for welding operations.
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 approach enables high-quality laser welding with reduced non-productive times, minimal metal spatters, and limited oxidation, while being cost-effective and robust, as it uses a laser beam for precise and controlled welds within a compact vacuum environment.
Implementation Method 1
an annular connection area between at least two workpiece parts of the workpiece, which is exposed to the vacuum in the welding chamber, is welded by a laser beam, with the laser beam propagating through the welding chamber
Implementation Method 2
the welding chamber is evacuated
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention comprises a method for the vacuum laser welding of an at least two-part workpiece (2), with the following steps: a) the workpiece (2) or a workpiece carrier (25), on which the workpiece (2) is arranged, and a set of welding goggles (3) are moved relatively towards one another and pressed against one another, so that a welding chamber (11) is enclosed and sealed in a gas-tight manner by the workpiece (2) and/or the workpiece carrier (25), the welding goggles (3) and a welding goggles holder (4), in which the welding goggles (3) are rotatably mounted; b) the welding chamber (11) is evacuated; c) an annular connecting region (18) between at least two workpiece parts (2a, 2b) of the workpiece (2) that is exposed to the vacuum in the welding chamber (11) is welded by a laser beam (49), wherein the laser beam (49) propagates through the welding chamber (11), and wherein the workpiece (2) or the workpiece carrier (25) together with the workpiece (2) and the welding goggles (3) are turned in relation to the welding goggles holder (4); d) air is admitted to the welding chamber; e) the workpiece (2) or the workpiece carrier (25) on which the workpiece (2) is arranged and the welding goggles (3) are moved relatively away from one another. The invention provides a method for the laser machining of at least two-part workpieces with which laser machining of a high quality can be performed with short downtimes.