Wire Feed Control for Stable Laser Deposition Contact Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In wire-based laser deposition welding, maintaining consistent contact pressure between the wire tip and the substrate surface is challenging, leading to potential overheating or undercooling of the melt, which affects the material application rate and energy input.
Innovation Solution
A method where drive and movement parameters of the wire conveyor device are detected using sensors, allowing the control device to regulate the conveying speed to maintain constant contact pressure, ensuring the wire tip is pressed onto the substrate surface with a consistent force, thereby controlling the material application and energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire feed speed is not controlled, then the material application process is simpler, but the contact force between wire tip and substrate surface becomes unstable leading to overheating or undercooling
Solution Approach 1:
The patent implements a feedback control system where a sensor detects the actual wire feed speed and feeds this information back to a control device. The control device compares the detected speed with the target speed and adjusts the wire feed mechanism accordingly. This closed-loop feedback ensures stable contact force between the wire tip and substrate surface, preventing overheating or undercooling while maintaining material application reliability.
Solution Approach 2:
The patent replaces manual or open-loop mechanical wire feeding with an automated control system that uses sensors and control algorithms. The mechanical wire feed device is integrated with electronic sensors and a control device that automatically adjusts feeding parameters based on detected conditions, substituting simple mechanical operation with a sophisticated control mechanism to achieve precise contact force regulation.
2Manufacturing precision
If the contact force is not maintained constant, then the device operation is simpler, but the material application rate becomes inconsistent affecting welding quality
Solution Approach 1:
The control device continuously monitors the wire feed speed through sensors and automatically adjusts the feed mechanism to maintain constant contact force. This feedback loop ensures that the material application rate remains consistent throughout the welding process, eliminating variations that would affect welding quality while removing the need for manual adjustment by the operator.
Solution Approach 2:
The system performs self-regulation of the wire feed speed based on detected conditions. The control device automatically compensates for variations in wire properties, feed mechanism wear, or other changing conditions without requiring external intervention. The system serves itself by detecting deviations and correcting them autonomously, maintaining precise material application rates.
3Productivity
If higher wire feed speed is used, then the material application rate increases, but the contact force becomes insufficient leading to incomplete melting
Solution Approach 1:
The patent implements dynamic adjustment of wire feed speed based on real-time detection of contact force and melting conditions. Rather than using a fixed high feed speed, the system continuously adapts the feed rate to maintain optimal contact force. This dynamic control ensures that even at high productivity levels, sufficient contact force is maintained to achieve complete melting and strong weld bonds.
Solution Approach 2:
The system dynamically changes the wire feed speed parameter based on detected conditions. When contact force is detected to be insufficient, the control device automatically reduces the feed speed to ensure proper contact and melting. This parameter adjustment allows the system to maintain high material application rates while ensuring adequate contact force for complete melting and strong weld strength.
4Strength
If lower wire feed speed is used, then the contact force is sufficient for complete melting, but the material application rate decreases reducing productivity
Solution Approach 1:
The system dynamically adjusts the wire feed speed to match the actual welding conditions and material requirements. Rather than using a consistently low feed speed, the control device continuously optimizes the rate based on detected contact force, wire properties, and melting characteristics. This allows the system to achieve high material application rates when conditions permit while ensuring sufficient contact force for complete melting when needed.
Solution Approach 2:
The control device dynamically changes the wire feed speed parameter based on real-time feedback. When high material application rates are required and conditions allow, the system increases the feed speed. When complete melting and strong bond formation are priorities, the system automatically reduces the feed speed to ensure adequate contact force. This adaptive parameter control reconciles the contradiction between productivity and weld strength.
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 ensures reliable and stable material application by preventing overheating or undercooling of the melt, allowing for precise adjustment of the material application rate and minimizing energy input into the substrate.
Implementation Method 1
the wire tip arranged on the substrate surface is melted by means of a radiation source
Implementation Method 2
at least one drive characteristic of the wire feed device is detected by means of a drive characteristic sensor
Implementation Method 3
at least one movement characteristic of the wire conveying device caused by the conveyed wire is detected by means of a movement characteristic sensor
Data Source
Figure 1
Figure 2
AI summary
The invention relates inter alia to a wire-based material application device (10, 100) with a wire feeder (20) for conveying a wire (30) having a wire tip (31) towards a substrate surface (62) of a substrate (60) at a conveying speed, wherein the wire tip (31) is pressed or is pressed against the substrate surface (62) with a contact force, with a radiation source (50, 70) for melting the material of the wire tip (31) of the wire (30) arranged on the substrate surface (62), wherein a drive parameter sensor (42, 44) for detecting at least one drive parameter of the wire feeder (20) and a control device (40) connected to the drive parameter sensor (42, 44) are provided, wherein the control device (40) is configured to control the conveying speed of the wire (30) depending on the at least one drive parameter of the wire feeder (20).