Welding Laser Power Detection Using Stable-Range Sampling
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Solution Overview
Problem
Current laser welding technologies face challenges in accurately detecting the power of welding laser light, leading to inconsistencies in welding quality due to interference from power samples outside the stable emission range and fluctuations during the ramp-up and ramp-down stages.
Innovation Solution
A method that involves obtaining power samples within a preset power range during the stable emission stage, processing these samples to determine average, minimum, and maximum power, and using these values to improve the accuracy of power detection results, while also determining the data volume upper limit and power threshold to prevent excessive processing and detect potential welding issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If power samples are collected during ramp-up and ramp-down stages, then more power samples are obtained, but measurement precision deteriorates due to interference from unstable power values
Solution Approach 1:
The patent applies preliminary action by pre-setting a stable power range threshold before collecting power samples. The system determines whether the laser is in a stable emission stage by checking if the current power value falls within this predetermined range, thereby filtering out unstable samples from ramp-up and ramp-down stages before they can affect the detection results.
Solution Approach 2:
The patent applies local quality by treating different power ranges differently. Only power samples within the stable power range are considered valid for detection, while samples outside this range are excluded. This selective approach ensures that only high-quality, stable power values contribute to the final detection result.
2Loss of information
If all power samples are processed, then complete power data is obtained, but device complexity increases due to excessive data processing
Solution Approach 1:
The patent applies the extraction principle by removing unstable power samples from the processing pipeline. By checking whether each power sample falls within the stable power range and excluding samples that do not meet this criterion, the system extracts only the relevant, stable data for further processing, thereby reducing the overall data volume and processing complexity.
Solution Approach 2:
The patent applies partial action by processing only a subset of power samples - specifically, only those within the stable power range. This selective processing approach avoids the excessive computation that would result from processing all collected samples, including the unstable ones during ramp-up and ramp-down stages.
3Productivity
If power detection is performed without stable power range filtering, then detection speed is maintained, but manufacturing precision deteriorates due to inclusion of unstable power values
Solution Approach 1:
The patent applies parameter changes by introducing a stable power range threshold as a filtering criterion. This parameter-based filtering mechanism allows the system to quickly identify and exclude unstable power samples without complex processing, thereby maintaining detection speed while improving the precision of the power measurement used for welding control.
Data Source
AI summary
Embodiments of the present application provide a method for detecting a power of a welding laser light and a laser welding system. The method for detecting a power of a welding laser light includes obtaining at least one power sample, wherein the power sample is obtained by sampling, every preset time period, the power of the welding laser light emitted by a laser. The method may further include acquiring a plurality of power samples within a preset power range in the at least one power sample. The method may further include processing the plurality of power samples within the preset power range to obtain power detection results.