Laser Welding Wire Oscillation for Precise Wire End Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser welding devices using added material face issues with wire mispositioning due to uncontrolled tension relief of the welding wire after a welding process, leading to suboptimal results, especially in multi-axial welding robots where frequent direction changes increase tension buildup.
Innovation Solution
A positioning device that sets the welding wire in an oscillating motion to control tension relief, ensuring the wire end is accurately positioned for the next welding process, and a drive system that combines feed and oscillating movements to maintain wire tension, with an optional laser beam for cutting the wire to precise length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding wire is fed through a flexible guide tube during the welding process, then the wire can be delivered continuously to the welding point, but the wire becomes tensioned and compressed inside the guide tube, leading to uncontrolled movement and mispositioning after the welding process
Solution Approach 1:
The patent applies mechanical vibration by oscillating the wire feed drive at a frequency of 10-1000 Hz with an amplitude of 0.1-10 mm. This vibration prevents the welding wire from becoming stuck or mispositioned in the guide tube by continuously disrupting the friction contact between the wire and tube walls, ensuring accurate wire end positioning after welding without compromising continuous delivery capability
Solution Approach 2:
The patent implements periodic action through alternating phases of wire feeding and oscillation. During welding, the wire is fed continuously; after welding, the wire feed drive switches to oscillating motion to retract and reposition the wire end accurately. This periodic switching between feeding mode and oscillation mode resolves the contradiction between continuous delivery and precise positioning
2Ease of operation
If a wire feed drive is used to deliver welding wire during the welding process, then the wire can be supplied as a function of consumption, but the wire becomes tensioned due to friction at the guide tube and wire nozzle, causing undefined movement when tension is reduced
Solution Approach 1:
The wire feed drive incorporates vibration capability that oscillates the wire during non-welding periods. This vibration actively prevents tension buildup by disrupting static friction at the guide tube and wire nozzle interfaces, ensuring the wire end remains stable and correctly positioned for the next welding operation while maintaining automatic supply during welding
Solution Approach 2:
The system uses feedback control where a sensor detects the wire end position and feeds this information back to the wire feed drive controller. Based on this feedback, the controller adjusts the oscillation parameters or feeding rate to maintain proper wire tension and position, resolving the contradiction between automatic supply and position stability
3Manufacturing precision
If the wire end is positioned in a welding readiness position before welding, then optimal welding results can be achieved, but after welding the wire executes undefined movement due to uncontrolled tension reduction, arriving at a position that differs from the desired welding readiness position
Solution Approach 1:
The patent uses mechanical vibration of the wire feed drive to actively control wire end positioning after welding. The oscillation at 10-1000 Hz with 0.1-10 mm amplitude ensures the wire end returns to and remains at the precise welding readiness position, preventing undefined movement and ensuring consistent positioning across multiple welding cycles while maintaining high positioning accuracy
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 solution enhances the reliability of laser welding by maintaining wire tension control, preventing mispositioning and ensuring optimal starting conditions for subsequent welding processes, even in complex robotic setups.
Implementation Method 1
a laser beam generated by a beam source is directed as a laser welding beam at a welding point
Implementation Method 2
Laser welding is performed with or without added material depending on the type of seam to be welded
Implementation Method 3
The welding wire is set in an oscillating motion in the longitudinal direction of the wire by a positioning drive
Implementation Method 4
Movement resistance opposing the feed movement of the welding wire at the guide tube and/or at the wire nozzle due to friction
Data Source
AI summary
Devices for laser welding using welding wire have a welding head, a wire guide for the welding wire, and a wire feed drive. The welding wire can be moved by the wire feed drive during a welding process with a feed movement in a feed direction, guided by the wire guide. A positioning device has a positioning drive, by which the welding wire is moved in an oscillating manner in the longitudinal direction of the welding wire, when a wire end of the welding wire is arranged in a welding readiness position. Methods for laser welding using a welding wire as added material are carried out using the devices. A control program controls the devices. The devices for laser welding can be provided as a part of a welding robot.