Patent Application
20200198254
The present disclosure relates to plastics welding and, more particularly, relates to assessing optical fibers in direct delivery welding and simultaneous laser welding applications.
This section provides background information related to the present disclosure which is not necessarily prior art.
Laser welding is commonly used to join plastic or resinous parts, such as thermoplastic parts, at a welding zone.
There are many different laser welding technologies. One useful technology is simultaneous through transmissive infrared welding, referred to herein as STTIr. In STTIr, the full weld path or area (referred to herein as the weld path) is simultaneously exposed to laser radiation, such as through a coordinated alignment of a plurality of laser light sources, such as laser diodes. An example of STTIr is described in U.S. Pat. No. 6,528,755 for “Laser Light Guide for Laser Welding,” the entire disclosure of which is incorporated herein by reference. In STTIr, the laser radiation is typically transmitted from one or more laser sources to the parts being welded through one or more optical waveguides which conform to the contours of the parts' surfaces being joined along the weld path. To ensure an accurate and comprehensive weld, the gap between any waveguide and the workpiece closest to the waveguide is kept as small as possible. Correspondingly, to improve efficiency, the gap between the delivery end of the fiber bundle and the waveguide is also kept as small as possible.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
The present technology provides a method for sensing the output of laser light intensity used to weld a plurality of work pieces in a simultaneous laser welding system. The method includes directing a laser source from a laser bank through a plurality of laser delivery bundles, wherein each of the plurality of laser delivery bundles are comprised of at least a laser delivery optical fiber. The plurality of laser delivery bundles deliver laser light through the at least the laser delivery optical fiber through a waveguide to the plurality of work pieces to be welded. A plurality of sensors is incorporated within the waveguide, and each sensor senses a laser light output by one of the plurality of the laser delivery bundles. In other embodiments, incorporating the plurality of sensors within the waveguide comprises incorporating at least a sensor positioned within the waveguide to sense laser light directed from a delivery end of at least an associated laser delivery optical fiber. In yet other embodiments, the incorporating a plurality of sensors within the waveguide comprises incorporating at least a sensor positioned within the waveguide to sense laser light in a direction substantially parallel to the direction in which laser light is delivered at the delivery end of the laser delivery optical fiber. In further embodiments, the plurality of sensors relays the sensed laser light output to a controller. In other such further embodiments, a user is alerted via the controller when a sensor senses that a laser light output by one of the plurality of the laser delivery bundles is below a predetermined parameter. In yet other such further embodiments, the laser light intensity of the laser delivery bundle is adjusted via the controller when a sensor senses that a laser light output by one of the laser delivery bundles is unsatisfactory. In even further embodiments, directing the laser source from a laser bank through a plurality of laser delivery bundles further comprises delivering laser light through a plurality of legs.
The present technology also provides a laser welding apparatus. The laser welding apparatus comprises a laser bank for outputting from a laser source laser light through a plurality of laser delivery bundles through a wave guide to a plurality of work pieces to be welded. Each laser delivery bundle comprises at least a laser delivery optical fiber. At least a sensor is incorporated within the wave guide for sensing the laser light output by one of said plurality of laser delivery bundles, and the at least a sensor relays the sensed laser light output to a controller. In other embodiments, the at least a sensor is positioned within the waveguide to face the delivery end of at least an associated laser delivery optical fiber. In yet other embodiments, the at least a sensor is positioned within the waveguide in a direction substantially parallel to the direction in which laser light is delivered at the delivery end of the laser delivery optical fiber. In further embodiments, the controller is configured to alert a user that a laser light output by one of said laser delivery bundles is below a predetermined parameter. In even further embodiments, the controller is configured to adjust the laser light output by one of said laser delivery bundles when the laser light output by one of the laser delivery bundles is unsatisfactory. In yet further embodiments, the at least a laser delivery bundle is comprised of a plurality of legs.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed, unless otherwise indicated.
When a component, element, or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially or temporally relative terms, such as “before,” “after,” “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.
It should be understood for any recitation of a method, composition, device, or system that “comprises” certain steps, ingredients, or features, that in certain alternative variations, it is also contemplated that such a method, composition, device, or system may also “consist essentially of” the enumerated steps, ingredients, or features, so that any other steps, ingredients, or features that would materially alter the basic and novel characteristics of the invention are excluded therefrom.
Throughout this disclosure, the numerical values represent approximate measures or limits to ranges to encompass minor deviations from the given values and embodiments having about the value mentioned as well as those having exactly the value mentioned. Other than in the working examples provided at the end of the detailed description, all numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein may indicate a possible variation of up to 5% of the indicated value or 5% variance from usual methods of measurement.
As used herein, the term “composition” refers broadly to a substance containing at least the preferred metal elements or compounds, but which optionally comprises additional substances or compounds, including additives and impurities. The term “material” also broadly refers to matter containing the preferred compounds or composition.
In addition, disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.
The technology according to the present disclosure provides methods and apparatuses for use in simultaneous laser welding. Under conventional methods for simultaneous laser welding and with reference to the prior art laser welder shown in
Under many aspects, the embodiments described according to the present disclosure may be used as part of an STTIr laser welding system. Referring again to
Referring to
Referring to
In any of the preceding embodiments, it is contemplated that sensor 40 may be positioned in a way in which sensor 40 directly intercepts at least a portion of the output of laser light delivered via a laser delivery optical fiber, as shown in
Further, where multiple laser delivery bundles 10 are contemplated (e.g., in STTIr applications), at least a sensor 40 may be integrated into waveguide 30 to intercept at least a portion of the output of laser light delivered via a laser delivery optical fiber, whereas at least another sensor 40 may be integrated into waveguide 30 to sense laser light reflected back from work pieces 60 during a weld cycle, as shown in
In further embodiments, the fiber feedback system further includes a closed control loop, as described in U.S. Pat. No. 7,343,218, which is commonly owned by the same assignee and is incorporated herein by reference.
Controller 104 can be or includes any of a digital processor (DSP), microprocessor, microcontroller, or other programmable device which are programmed with software implementing the above described logic. It should be understood that alternatively it is or includes other logic devices, such as a Field Programmable Gate Array (FPGA), a complex programmable logic device (CPLD), or application specific integrated circuit (ASIC). When it is stated that controller 104 performs a function or is configured to perform a function, it should be understood that controller 104 is configured to do so with appropriate logic (such as in software, logic devices, or a combination thereof), such as control logic shown in the flow charts of
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This application claims the benefit of U.S. Provisional Application No. 62/511,403 filed on May 26, 2017. The entire disclosure of the above application is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US18/34187 | 5/23/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62511403 | May 2017 | US |
