Vehicle Light Laser Welding with Localized Fibre Power Control
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Solution Overview
Problem
Conventional simultaneous laser welding techniques for vehicle lights are complex, slow, and costly due to significant light power losses and inability to locally manage light power, especially when dealing with complex shapes, leading to high tooling times and costs.
Innovation Solution
A simultaneous laser welding apparatus using a plurality of laser diodes, each with its own optical fibre, directing light beams through a light guide to individually adjust and focus power at specific points along the welding interface, reducing power losses and allowing for precise energy distribution based on the geometry of the vehicle light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser source is connected to a bundle of optical fibres to perform simultaneous laser welding, then the welding can be performed over the whole interface simultaneously, but significant light power losses occur (around 30%) and the light power cannot be locally managed
Solution Approach 1:
The patent divides the single laser source system into multiple independent laser diodes (e.g., 3-5 separate laser diodes), each connected to its own optical fibre. This segmentation eliminates the power loss associated with beam splitting in a single bundle while maintaining simultaneous welding capability across the interface. Each laser diode operates independently, delivering full power to its designated region without the 30% loss incurred in traditional bundled approaches.
Solution Approach 2:
The patent implements local power management by assigning each laser diode to a specific region or point along the welding interface. This allows the light power to be locally adjusted and optimized for each segment of the interface, enabling precise control over the welding process at different locations while maintaining overall simultaneous operation. The system can adapt power distribution to match the specific geometric and material requirements of each local area.
2Productivity
If a bundle of optical fibres is used to distribute laser beams, then simultaneous welding over the interface is achieved, but the complexity of the apparatus increases and power losses occur
Solution Approach 1:
The patent replaces the complex bundled fibre structure with multiple simple, individual optical fibres, each connected to its own laser diode. This segmentation simplifies the overall system architecture by eliminating the need for complex beam splitting and fibre bundle management, while still achieving simultaneous welding through coordinated operation of multiple independent laser-fibre pairs.
Solution Approach 2:
The patent combines multiple simple laser diode-fibre units into a coordinated system that achieves the functionality of a complex single-source bundle system. By merging several independent, simple components, the system achieves simultaneous multi-point welding without the complexity and power losses inherent in traditional bundled approaches.
3Reliability
If maximum light power is sent to all portions of the welding interface to ensure quality at the most critical point, then welding quality is maintained, but tooling times and costs increase significantly
Solution Approach 1:
The patent applies local power management where each laser diode's output is independently controlled and optimized for its specific region of the welding interface. This allows the system to deliver appropriate power levels locally rather than uniformly applying maximum power everywhere. Critical areas receive sufficient power for quality welding, while less critical areas receive optimized power levels, reducing overall tooling time and costs while maintaining welding quality where it matters most.
Solution Approach 2:
The patent enables dynamic adjustment of laser power parameters for each individual laser diode based on local requirements. By changing the power parameter locally rather than globally, the system optimizes the balance between welding quality and processing time, avoiding the inefficiency of applying maximum power uniformly across the entire interface.
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 significantly reduces power losses to about 1-2% compared to 30-35% in traditional methods, enables efficient welding of complex geometries, and ensures a mechanically resistant and long-lasting welding joint with localized power control, thereby lowering costs and improving welding quality.
Implementation Method 1
the container body acts as absorbing element towards the light beam emitted by the laser source
Implementation Method 2
a plurality of laser diodes (44) suitable for emitting light beams
Implementation Method 3
The lenticular body substantially transmits the laser beam therein incident without absorbing it
Implementation Method 4
The laser beam is absorbed at the welding interface by the perimeter edge of the container body which is heated up to softening
Data Source
Figure 1
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AI summary
A simultaneous laser welding apparatus (36) of a vehicle light (4) comprising a placement support (40) for a container body (8) and a lenticular body (24) of a vehicle light (4) to be welded together at reciprocal perimeter profiles (20,28) associated at a welding interface (32), a plurality of laser sources (34, 44) suitable for emitting light beams, a plurality of optical fibres (48) associated with the laser sources (34, 44) at input ends (52) and suitable for transmitting said light beams, a fibre-holder support device (60) for the optical fibres (48), suitable for blocking output ends (56) of said optical fibres (48) in predetermined positions, spaced apart by a pitch (P), a light guide (64) provided with at least one seat (76) which extends from a light input wall (68), which receives the light beams coming from the output ends (56) of the optical fibres (48), to a light output wall (72) which sends the light beams towards the welding interface (32). Advantageously, a single optical fibre (48) is associated at its input end (52) with each laser source (34, 44) so as to receive, channel and transmit towards the welding interface (32), the light beam produced by said corresponding laser source (34, 44).