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Module 3: Machine Module 3: Machine Operation & Cutting HeadOperation & Cutting HeadL3050 Laser Maintenance I

June 2004

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Learning Objectives

Name all elements on the MMC panel.Perform basic machine operation:

Start up, warm up, and shut down the laser according to standard procedure.Load and access cutting programs.Back up, add a new, back up a new, and restore corrupted tech tables according to standard procedure.Reset a lens error.

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Learning Objectives

Identify and perform operator’s responsibilities:

1. Clean and check final lens2. Install correct head in to machine3. Install proper nozzle4. Nozzle Alignment5. Focus Test

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MMCMachine Controls

Color Display

Control Elements

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Control ElementsProduction

Set up

Programming

Set up (not used)

Maintenance

Diagnostics

Exit Windows

Help

Number Buttons

Backspace

Escape

Enter

Zoom

Recall

Page up

Page down

Focus menu/Fast Key

TAB

Cursors and Toggle

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Machine Elements

Machine On/off

Establish initial

position

Jog keys

Light Barrier

Feedhold

Reset

Start/Release Feedhold

Cycle start

Laser On/off

Beam On/off

Beam trap Open/close

Laser Reset

Laser Test

Potentiometer feed rate

Potentiometer cutting gas

pressure

Key switch-Beam block

Key switch-Service mode

E-stop

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113 -- Zero point offset114 -- Switch elements (for Pallet, Laser,

and Selections)117 -- LiftMaster131 -- NC management (edit & delete)132 -- File management (a/c/d drives or

network drives)123 -- Manual data input124 -- Laser status1151 -- Technology tables1152 -- Laser power cycles (piercing)1153 -- Sheet load/measure

Focus Keys Menu

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1155 -- Sheet tech1156 -- Cat-Eye measurement154 -- Warm Start156 -- Inch/metric set157 -- Maintenance Logbook22 -- I/O diagnostics25 -- Diagnostics262 -- Leak Test31 -- Help32 -- Operator Manual33 -- Programming Manual

Focus Keys Menu

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1. O p eratio n 2.D iagnostics 3 .H e lp

1 . Laser T echnology

2 . Laser P ow er C yc les

3 . Load S heet

4 . R eserve

5 . S heet T echno logy

6 . M easuring C yc le

7 . R eserve

1 . N C P rogram M anagem ent

2 . F ile M anagem ent

3 . N C P rogram

4. R eserve

Legend :G rey boxes ind ica te func tion is unava ilab le .B o ld text ind ica tes o ther branches in the tree .

1 . S ing le Job

2 . C om ponents o f M ach ine

3 .P rogram O ptions

4 . S w itch E lem ents

5. Tab les

6. P roduction P lan

7 . L ift m aster (30 /40 /6030 on ly)

1 . S ing le Job

1 . S w itch E lem ents

2 . Jog M ode

3. M D A

4. A d jus t Laser B eam

5. L ift m as te r (30/40 /6030 on ly)

1. P ro d u ctio n

2. S etu p

3. P ro g ram

4. R eserve

5. M ain ten an ce / S tartu p

1. M ach ine D ata

2 . B ackup o f D a ta

3 . Load S o ftware

4 . C om ponents o f M ach ine

5 . M M C A pp lica tions

6 . D isp lay

7 . M a in tenance Logbook

8 . R eserve

9 . R eserve

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2.Diagnostics

1. S W Logbook

2. PLC Debugger

3. DDE Debugger

4. SQL Interpreter

5. MMC Start Automatic Machine

6. End

1. Telegram Diagnostics

2. MMC Telegrams

3. TC Cell Telegrams

4. NCK Telegrams

1. RF Generator

2. Leakage Test

1. Operation 3. Help

1.Fault Diagnostics

2. I/o Diagnostics

3. File Functions

4. Service

5. Remote Diagnostics

6. Laser

7. Display Original Position

1. Version Display

2. Development

3. NCK Diagnostics

4. Analyzer

5. PLC Diagnostics

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2.Diagnostics1. Operation 3. Help

1. Use Help

2. Operating Guide

3. Programming Guide

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Tech Tables

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Laser Tech Tables

TC_Laser_On Statement

()

Contour

1 - Large2 - Medium3 - Small4 - Vaporizing5 - Marking6 - Point Mark

1, , ,TC_LASER_ON 1

Laser Method

1 - Pierce and Cut w/ Height Regulation2 - Pierce and Cut w/o Height Regulation3 - Pierce w/o Cut w/ Height Regulation4 - Pierce w/ Cut w/o Height Regulation5 - Cut with Height Regulation6 - Cut w/o Height Regulation7 - Pierce w/ Height Regulation, Beam OFF8 - Pierce w/o Height Regulation, Beam OFF9 - Pierce w/o Ramp Cycle and Cut w/ Height

Regulation (SprintLas, Common Cut)11 - Cut w/ Height Regulation (SprintLas,

Common Cut)12 - Cut w/o Height Regulation (SprintLas,

Common Cut)

"11215"

Tech Table

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Pierce Type

0 - No Piercing10 - Normal11 - Gentle Piercing20 - Point Marking30 - Soft Microweld31 - Hard Microweld

0

Cutting Speed

0 - Normal1 - Reduced from

Pierced Hole2 - Reduced from

Pre-punched Hole3 - Reduced for Thick

Sheet

0

Acceleration

0 - Normal1 - Reduced2 - High

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Tech Tables (old)

" "1

Material

1 - Steel2 - Stainless Steel3 - Aluminum

1 2

Material Thickness

12 = .120"07 = .070"

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ResonatorSize

1 - 1.8k or 2.0k2 - 2.2k3 - 2.4k or 2.7k4 - 2.6k5 - 3k or 3.2k6 - 3.8k7 - 4k

1

Assist Gas Type

1 - O22 - N23 - Compressed Air

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Alpha-Numeric Tech Tables (new)

" "AL

Material Type

AL - AluminumSS - Stainless SteelST - Mild steel

012

Material ThicknessExample:

100 = 1.000 inch050 = 0.500 inch025 = 0.250 inch012 = 0.120 inch004 = 0.040 inch

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Resonator Size

20 - 2000k27 - 2700k32 - 3200k40 - 4000k50 - 5000k

N

Assist Gas Type

A - Shop airO - OxygenN - Nitrogen

N

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Laser Power Cycles (1-1-5-2)

Use to control timing and power during pierce cycle.Up to 99 power cycles:

Typically only 4 cycles used

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Load Sheet Technology (1-1-5-3)

Use to automate sheet load and measure cycles.Loading unit set to 5causes pallet change before sheet is cut.Can be set by part program via file split.

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Sheet Measure Technology (1-1-5-4)

These are the dimensions use to measure the sheet.They can be loaded via the part program during the file split.

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Sheet Measure Technology (1-1-5-4)

These are the dimensions use to measure the sheet.They can be loaded via the part program during the file split.

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840D File Management

There are two (2) places part programs are stored in MMC:

File Manager FK132NC Manager FK131

Part programs must be split to be stored in the NC Manager:

Split files separate the part program from the tech tables

Part programs need to be selected one at a time from the production screen to run in the NCK.

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840D File Management

In order to assemble an edited part program, you must press the output program soft key in the file manager area:

This will bring you to the NC manager screen

From there, you will press the generate master file soft key.

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File Management (before splitting)

File Management (132).Use TAB key to move around File Management Screen.Files need to be split in order to move them to the NC program manager.

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NC program manager (131).

Select program from Production Screen.

File Management (after splitting)

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Drive A:FK 132

FileManagement

<Copy File>

FK 131NC Manager NCK

1 program at a time<Select Program>

<Split Master File>

Laser TechTable

Sheet TechTable

<Split Master File>

Other TechTables

<Output Program>

Production Screen

840D File Management Structure

<Select Program>

<Generate Master File>

<Generate Master File>

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Basic Machine Operation

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Basic Machine Operation

Standard start-upLaser warm-upLaser shut-down (manual/automatic)Load programs (assessing programs)Access tech tablesReset lens errorsEdit production plan

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Practice

Follow the Student Guide, practice these procedures under your instructor’s guidance:

Standard machine start-upLaser warm-upLaser shut-down (manual/automatic)Load programs (assessing programs)Access tech tablesReset lens errorsEdit production plan

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Cutting Head

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1

3

1 X adjustment screw with scale2 Clamping pin3 Y adjustment screw with scale4 Nozzle

256133

Ident-Nr.

0001Serien-Nr.

5"D1,5" HD

0001

2

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Laser Cutting Head

Height insures a constant standoff between nozzle and material.Quick cutting Regulation.DIAS head change.Fast and precision adjustment by means of micrometer screws and dial indicator.Change of lenses or cutting head reduced to a minimum.Nozzle cooled with compressed air.

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Before Cutting

90% of power is reflected10% of power is absorbedMaterial melts immediatelyMolten pool is called “The Keyhole”

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As Cutting Starts

“The Keyhole” is blown away by the assist gas10% of power is reflected90% of power is reflected

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During Cutting

Cutting begins when the beam is through the material.The beam or workpiece, or both, must move to create the desired cut path.

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Operator’s Responsibilities

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Operator’s Responsibilities

1. Clean and check final lens.2. Install correct head in to machine:

Always check final lens for your reflection.Remember to remove plastic cover.Check O-rings for leaks.

3. Install proper nozzle.4. Nozzle Alignment:

Center beam to hole in nozzle.5. Focus Test.

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Laser Cutting Head

Use special tool to remove and install cutting head.

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Usually .8, 1.0, 1.4, 1.7, 2.0, 2.3mm sizes.Low Pressure Nozzles:

0-6 barUsed for Sublimation and Flame cutting

High Pressure:6-20 barUsed for Fusion and N2

Nozzle hole center to beam alignment:Must be checked after cutting head is installed.Laser beam must be in center of nozzle hole.

Nozzles

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Nozzle Alignment

When?Replacing a cutting headAfter cleaning and/or changing the focusing lens on the cutting head

Why? Misalignment of nozzles results in unequal distribution of assist gas stream around the beam.Kerfs will not be properly formed resulting in dross on at least one or two sides of the cut piece.

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Focus

5.0 inch for material .25 inches (3/16) and under

Focus is adjusted to –3mm below nozzleHas a .006 inch kerf

7.5 inch for material over .25 (3/16) inches

Focus is adjusted to –5mm below nozzleHas a .010 inch kerf

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Focus Test

Needs to be done when replacing a lens or having cut problemsAll lens are not made perfectly the same

The lens are made much better than beforeUse to find the center of AutoLas adjustmentAutoLas is an adjustable mirror on top of Z-axis

Uses cooling water pressure to adjust mirror focusTo run Focus Test

You need 1mm sheet steelCP_FOCUS_COMB program

1 122Middle

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Practice

Follow the Student Guide, practice these procedures under your instructor’s guidance:

Clean and check final lensInstall correct head in to machineInstall proper nozzleNozzle AlignmentFocus Test

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Questions?