METHOD AND LASER PROCESSING MACHINING FOR LASER WELDING A FIRST AND A SECOND WORKPIECE PORTION
20200030909 ยท 2020-01-30
Inventors
Cpc classification
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
B23K26/064
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0869
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
B23K26/32
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/064
PERFORMING OPERATIONS; TRANSPORTING
B23K26/70
PERFORMING OPERATIONS; TRANSPORTING
B23K26/08
PERFORMING OPERATIONS; TRANSPORTING
B23K26/32
PERFORMING OPERATIONS; TRANSPORTING
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates to methods for laser welding a first and a second workpiece portion with a laser beam that is guided using a laser machining head along a joining gap formed between the workpiece portions, in which method the laser beam is focused and a filler is lined up with the joining gap. At least one gap width of the joining gap of the workpiece portions to be welded is detected and evaluated along the course of the joining gap and compared with at least a first and a second gap measurement. If a detected gap width is within the first gap measurement, the feeding of the filler to the joining gap is stopped and a beam profile of the laser beam is set with a point or annular focus, and if a detected gap width is within the second gap measurement, a feeding of the filler is actuated.
Claims
1-25. (canceled)
26. A method of laser welding a first and a second workpiece portion with a laser beam guided along a joining gap formed between the workpiece portions by a laser processing head, comprising: focusing the laser beam with a processing optical system; supplying an additional substance aligned in relation to the joining gap; detecting at least one gap width of the joining gap of the workpiece portions to be welded; evaluating the detected gap width along the course of the joining gap and comparing the detected gap width with at least one first and one second gap size, wherein the first gap size comprises a gap width in which a welded seam is formed without the additional substance, and the second gap size comprises a gap width with which the additional substance is supplied for the formation of the welded seam for filling the joining gap; shutting down, with a detected gap width being within the first gap size, the supply of the additional substance to the joining gap during the laser welding, and setting a beam profile of the laser beam with a point or ring focus; and controlling, with a detected gap width being within the second gap size, the supply of the additional substance to the joining gap, and setting a beam profile of the laser beam with a ring focus.
27. The method of claim 26, wherein detecting the joining gap comprises detecting the joining gap by a sensor system during a teach-in mode for detecting the course of the joining gap or immediately before introducing the welded seam coaxially relative to the laser beam or in advance.
28. The method of claim 26, wherein the first gap size is selected based at least on a material thickness of the workpiece portions to be welded, and the first gap size is smaller than the material thickness of the workpiece portions to be welded, and wherein the first gap size is equal to or less than a share of 15% of the material thickness of the workpiece portions to be welded.
29. The method of claim 28, wherein the first gap size is equal to or less than a share of 10% of the material thickness of the workpiece portions to be welded.
30. The method if claim 26, wherein the additional substance is supplied to the joining gap in advance in the welding direction in relation to the beam axis of the laser beam.
31. The method of claim 26, wherein the additional substance comprises one of an additional wire supplied via a wire supply device or a powder supplied via at least one nozzle, to the laser beam.
32. The method of claim 26, further comprising forming an annular beam surface by the beam profile of the laser beam having a ring focus, said beam surface covering the joining gap, and delimiting an inner beam-free region by an inner beam surface edge, said region being substantially corresponding to the width of the joining gap or wider, and an outer beam surface edge of the annular beam surface covering the two edges of the workpiece portions to be welded.
33. The method of claim 32, wherein supplying the additional substance comprises supplying the additional substance in a beam surface portion of the annular beam surface of the laser beam that is formed by a region of the annular beam surface that is in front in the advance direction and covers the joining gap.
34. The method of claim 32, further comprising heating, in a beam surface portion of the annular beam surface, a molten mass formed in the advance beam surface portion, said beam surface portion being behind and covering the joining gap.
35. The method of claim 32, further comprising setting the width of a beam surface portion of the annular beam surface of the laser beam above or below a plane of the workpiece portions to be connected by a distance apart of the focal point, said beam surface portion covering the joining gap.
36. The method of claim 32, wherein the beam profile of the laser beam is formed with a ring focus by at least one of a 2-in-1 fiber, a 3-in-1 fiber, an axicon, or an N-in-1 fiber.
37. The method of claim 32, wherein supplying the additional substance comprises supplying the additional substance to the joining gap by a supply device, the supply device aligned on a supply axis in relation to the joining gap, the method further comprising: coupling the laser beam into a movement device arranged on the housing by the housing and transferred into a beam axis of the movement device; and rotatingly driving the beam axis of the movement device corresponding to the course of the joining gap in the welding direction around the supply axis of the additional substance; and crossing the beam axis across the additional substance in the joining gap during the rotational movement of the movement device.
38. A laser processing machine comprising: a laser source; a processing head; a beam guide that extends between the laser source and the processing head; a processing optical system; and a supply device that supplies an additional substance to a joining gap; wherein the laser processing head is configured to direct a laser beam towards the joining gap, said joining gap being formed between a first and a second workpiece portion to be welded; wherein the supply device has a supply nozzle that lies on a supply axis and supplies the additional substance to the joining gap, wherein the processing head comprises a movement device, by means of which the laser beam guided along a main axis is deflected above the joining gap and is transferred into a beam axis in the movement device, which is aligned at an angle to at least one of the main axis or the supply axis, and crosses the joining gap, and wherein the movement device is provided rotatingly around the main axis or supply axis.
39. The laser processing machine of claim 38, wherein the supply axis of the supply device is configured to at least one of (1) run in parallel to the main axis or (2) lie on the main axis.
40. The laser processing machine of claim 38, wherein the main axis is formed perpendicularly to the joining gap.
41. The laser processing machine of claim 38, wherein the movement device is mounted at an angle of one of at least +/90, at least +/135, or at least +/180, rotatably around the main axis by a rotation mount.
42. The laser processing machine of claim 32, wherein the movement device has at least one of a deflection mirror and a processing optical system and a protective glass arranged on the beam output side.
43. The laser processing machine of claim 32, wherein a fiber comprising several coaxial ring fibers is provided for generating a beam profile of the laser beam having a ring focus, the fiber comprising at least one of a 2-in-1 fiber, a 3-in-1 fiber, or an N-in-1 fiber.
44. The laser processing machine of claim 32, further comprising: a machine control device; and a laser control device; wherein the machine control device is configured to shut down the supply device of the additional substance in the event of a detected gap width that lies inside the first gap size, and wherein the machine control device controls the supply device for supplying the additional substance in the event of a detected gap width that lies within a second gap size, and wherein the laser control device controls a beam profile of the laser beam having a point or ring focus.
45. The laser processing machine of claim 32, wherein the machine control device is configured to compare a detected gap width along the course of the joining gap to a first and a second stored gap size and evaluate the detected gap width.
Description
DESCRIPTION OF DRAWINGS
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DETAILED DESCRIPTION
[0047] In
[0048] A laser device of the laser processing system 3, said laser device not being explicitly shown in
[0049] Further components of the tool machine 1 comprise, for example, a rotation changer 13 for holding workpieces to be processed and for easily removing processed workpieces, a compact dust catcher 15 for sucking up smoke gases and suspended particles from the inner chamber, a scrap conveyor 17 and integrated elements not explicitly shown for the pneumatics, for the cutting and welding gas supply and for the central lubrication. Furthermore, a light grid 19 can delimit an external access region in relation to the rotation changer 13.
[0050] A work duration controlled by the machine control system allows the processing of the workpiece in a predetermined manner by the various components of the laser processing machine interacting.
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[0052] The beam guide components comprise, for example, a laser light cable 22, a collimation optical system 51 and a processing optical system 66 for leading and focusing the laser beam 21 onto a workpiece 24. At least the processing optical system 66 is usually provided in a processing head 7, which can be substantially freely positioned and aligned, and emerges from the laser beam 21. Preferably, the collimation optical system 51 is also provided in the processing head 7. In particular, the processing head 7 can adopt any adjustable position and orientation in a region determined by the X, Y and Z slots 26, 27, 28 and the rotational joints 29, 30. Drive units are allocated to the X, Y and Z slots 26, 27, 28 and the rotational joints 29, 30, said drive units allowing a relative movement of the processing head 7 to be carried out in relation to the workpiece 24. From this, a working space emerges, which comprises all points that can be processed by the emerging, correspondingly focused laser beam 21.
[0053] Media supply components are, for example, a supply device 69 for an additional substance and/or protective or process gas, and one or more supply nozzles 71, which are fixed, for example, on the processing head 7.
[0054] In the embodiment according to
[0055] The laser processing system 3 is suitable for processing planar sheets, as well as three-dimensional, variably moulded workpieces, such as remoulded sheets, for example, in a cutting, welding or heating manner. Alternatively to the embodiment depicted, a machine having a 6-axis buckling arm robot, for example, would also be able to carry out these tasks.
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[0057] According to
[0058] In
[0059] The use of a 2-in-1 fibre 37 is only exemplary. Alternatively, a 3-in-1 fibre, i.e. a fibre with an additional further ring profile, can also be provided. Similarly, alternatively to the step index fibre described, it is possible to use a gradient index fibre.
[0060] In
[0061] A movement device 55 is provided on the housing 16 of the laser processing head 7, which can preferably be rotatably arranged around the main axis 56. Preferably, a rotatable mount 57 is provided in order to rotatably receive this movement device 55 around the main axis 56. This movement device 55 comprises optical elements, by means of which the laser beam 21 is decoupled from the main axis 56 by the laser processing head 7 and transferred into a beam axis 59. This beam axis 59 is directed towards a joining gap 60, which is formed by two workpiece portions 61, 62 to be welded. This beam axis 59 is inclined in relation to the main axis at an angle of 5 to 45. An angle between 7 and 15 is particularly preferred, since here a good coupling into the material is ensured and back-reflections into the laser optical system can be avoided.
[0062] The rotation mount 57 can preferably also be provided with a coupling in order to be able to receive differently formed movement devices 55. As a result, optical systems for other processing tasks, such as laser cutting or surface treatment, can also be rotatably fixed on the housing 16.
[0063] The movement device 55 comprises a first and at least one further deflection mirror 63, 64, and a processing optical system 66, which focuses the laser beam 21 and preferably also a protective glass 67, by means of which the processing optical system 66 is protected from contamination. A focus 83 of the laser beam 21 can be set by the processing optical system 66 and/or the collimation optical system 51, said focus 83 being able to be both above, at surface height, or below the joining gap 60 of the workpiece portions 61, 62, as is explained further below by means of
[0064] A supply device 69 can be arranged lying on the main axis 56 by the radially lateral decoupling of the laser beam 21 by the movement device 55. Preferably, this supply device 69 comprises a supply nozzle 71, which is preferably positioned on the main axis 56 via a holder 72 fixedly arranged on the housing 16. An additional substance 73 can be supplied for the welding process. In the exemplary embodiment according to
[0065] The additional substance 73 is preferably supplied by the positioning of the supply nozzle 71 on the main axis 56 perpendicular to the surface of the workpiece portions 61, 62 or perpendicular to the joining gap 60.
[0066] Another line laser 75 or further optical systems can additionally be provided on the holder 72. The alignment of these optical systems is in such a way that these are directed towards the welding point. The welding point is defined by the laser beam 21 hitting the joining gap 60.
[0067] Furthermore, an optical sensor system 54 can be provided in or on the laser processing head 7 in order to detect the welding point or the joining gap 60 and/or the line laser 78 projected onto the workpiece. An uncoupled beam can be supplied to the sensor system 54, such as a camera, in particular a CCD camera, for example, via a decoupling element 53, for detecting the joining gap 60, which forwards the signals obtained from this to the control device 31, 32.
[0068] Furthermore, a nozzle, in particular a linear nozzle 76, can be provided on the movement device 55, through which linear nozzle 76 protective gas flows out in the direction of the components 61, 62 onto the welded seam. In doing so, the fresh welded seam upper beam is shielded from oxygen from the atmosphere in the cooling phase. In addition, a part of the protective gas preferably flows in the direction of the shifting movement 77 of the laser processing head 7 during the laser welding in order to also already shield the process point from the atmosphere. The protective gas supply could alternatively also be attached to the holder 72 in order to enable a better accessibility; to do so, nozzle forms other than a linear nozzle are also possible.
[0069] In
[0070] In
[0071] The laser welding of the two workpiece portions 61, 62 is controlled by the machine control device 31 and/or the laser control device 32. Preferably, the workpiece portions 61, 62 are positioned in relation to one another in such a way that the width of the joining gap 60 is virtually equal to zero. However, this cannot often be successfully implemented because of processing tolerances or further requirements. Therefore, the joining gap 60 is of a different width. An adjustment to the changing situations can be carried out immediately by the arrangement of the laser processing head 7, the detection of the joining gap 60 before the formation of the welded seam 81 and the change of the beam characteristic of the laser beam from a ring focus 43 into a point focus 46 and vice versa with the welding method described below by means of
[0072] Before the joining gap 60 formed by the workpiece portions 61, 62 to be welded is welded, the course and/or the width of the joining gap can be detected by a teach-in method. To do so, the line laser 25 can be used, which is arranged in advance on the laser processing head 7 and is detected by a sensor system which is attached to the processing system in or on the laser processing head 7 in the machine. In
[0073] When detecting a first gap size of a joining gap 60, which, for example, is smaller than the material thickness of the workpiece portions 61, 62 to be welded, the coupling of the laser beam 21 into the beam guide 22 is controlled in such a way that the laser beam has a beam profile having a point focus 43. At the same time, the supply device 69 for the additional substance 73 is shut down. Then, the laser processing head 7 is shifted along the course of the joining gap 60, and the welded seam 81 is formed in order to close the joining gap 60. If there is no teach-in mode before the welding process, at least the gap width of the joining gap 60 is monitored and requested by the sensor system 54 during the laser welding.
[0074] If the gap width of the joining gap 60 changes such that a gap width is detected which is greater than then first gap size, the welding parameters are changed by means of the machine control device 31 and/or laser control device 32. The supply device 69 is controlled in order to also guide the additional substance. Furthermore, the beam characteristic of the laser beam 21 is changed from a point focus 43 into a ring focus 46. Further parameters, such as laser intensity, for example, can also be adjusted.
[0075] With a welding of the workpiece portions 62, 63 with an annular beam profile of the laser beam 21, the additional substance 73 is arranged in advance of the laser beam 21. The ring focus 46 is preferably set in such a way that the focal point 83, for example, lies on the workpiece plane of the workpiece portions 61, 62 (
[0076] Supplying the supply substance 73 takes place in such a way that the advance beam surface portion 86 crosses the additional substance 73 or the additional substance 73 is supplied to the joining gap 60 in such a way that it is inside the beam surface portion 86. As a result, a melting of the additional substance 73 as well as of an edge contour and the workpiece portions 61, 62, and the formation of a welded seam 81 is obtained in this region. As a result of the beam surface portion 87 behind, the melting bath formed in advance of the surface portion is warmed by the beam surface portion 87 behind. As a result, the cooling speed can be reduced, whereby an improvement of the quality of the welded seam 81 is achieved.
[0077] The schematic depiction of the laser beam 21 aimed at the joining gap 60 and of the additional substance 73 in
[0078] In
[0079] In
[0080] To further discuss the method, four welding positions 91 to 94, for example, are depicted, which are described below. In the welding position 91, there is a fall formation, as is described in
[0081] With a shifting movement from the welding point 91 to the welding point 92, the ring focus 46 can be simply adjusted to the course of the joining gap 60 by a rotational movement of the movement device 55 as a result of the movement device 55 provided rotatingly in relation to the housing 16. To control the laser processing head 7, it applies that the main axis 56 runs in the joining gap 60.
[0082] From the welding point 92 to the welding point 93, the width of the joining gap 60 has a first gap size, for example. As a result, the joining gap 60 widens out in turn, such that, in turn, conditions are set based on the welding point 93 up to welding point 94, like between the welding point 91 and 92, in order to connect the widening joining gap 60 to a welded seam.
[0083] In