Handheld laser welding machine instruction manual
(welding head and wire feeder)
The manual for the welding head of the handheld laser welding machine is as follows:
Overview :
This manual covers the basic installation, factory settings, operation and maintenance services of welding head products .
This product covers handheld laser welding machine guns and self-developed control systems, and is equipped with multiple safety alarms and active safety power-off and light-off settings. This product can be adapted to various brands of fiber lasers; the optimized optics and water-cooling design make the laser welding gun head work stably for a long time under 2000W
1. Basic features: self-developed control system, multiple safety alarms, smaller size, flexible operation, easy to use
2. More stable: all parameters are visible, real-time monitoring of the whole machine status, avoiding problems in advance, more convenient troubleshooting and solving problems, and ensuring the stable operation of the welding head
3. Process: all parameters are visible, the welding quality is better, the deformation is small, and the penetration depth is high
4. Stable parameters and high repeatability: As long as the laser power is stable, the process parameters must be repeatable if the nozzle air pressure and lens state are determined. Greatly improve efficiency, but also reduce operator requirements
1.1 Operating environment and parameters
Power supply voltage (V)220±10%VAC50/60Hz
Placed in a flat environment, free from vibration and shock
Working environment temperature (°C) 10~40
Working environment humidity (%)<70
Cooling method water cooling
Applicable wavelength 1064nm (±10nm)
Applicable power≤2000W
Collimation D20*5/F60
Focus D20*4.5/F150
Reflection 30*14T2
Protective mirror specification 18*2
Maximum support air pressure 10 bar
Focus vertical adjustment range ±10mm
Light shift adjustment range Line0-5mm
Weight SUP15S 1 25KG/SUP20S 0 8KG
1.2 Attention information
1) Ensure reliable grounding before power supply
2) The laser output head is connected with the welding head, please carefully check the laser welding and laser output head to prevent dust or other pollution, and use special lens paper when cleaning the laser output head.
3) If the equipment is not used according to the method specified in this manual, it may be in an abnormal working state and cause damage.
4) When replacing the protective mirror, please make sure to protect it well
5) Please note: when using for the first time, when the red light cannot come out from the copper nozzle, be sure not to emit light
2.1.1 Controller power supply terminal
The power supply end uses a 5P interface, using a random 24V switching power supply and a 15V switching power supply for power supply
Please note that the 15V switching power supply distinguishes the positive and negative poles, Ⅵ1 is connected to 15V+, V2 is connected to 15V-, any COM on the 15V switching power supply is connected to pin 2 GND
Please note that the switching power supply must be grounded
2.1.2 Controller LCD screen terminal
The wiring of the LCD screen is included with the machine, just connect it directly, see the picture above for the specific definition
2.1.3 Controller signal interface 1
Signal interface 1 end uses 8P interface, ready for signal correlation
The ①/② pins are the air pressure alarm signal input. If you need to enable it (wiring is required), please set the air pressure alarm level to high in the background, otherwise it is low
The ③/④ pins are the water tank alarm signal input. If you need to enable it (wiring is required), please set the water tank alarm level to high in the background, otherwise it is low
The ⑤ pin is the reference ground of the safety lock, which is directly connected to the workpiece with a wire
⑥ The pin is the safety lock of the welding head, connected to the blue wire of the three-core wire, when the welding head touches the workpiece, the safety lock is on at this time
⑦ The pin number is the switch of the welding head, which is connected to the brown wire of the three-core wire
The ⑧ pin is the light switch of the welding head, connected to the black wire of the three-core wire, when the trigger is pulled, the trigger button is on
Please note that only when there is no alarm and the signal of the safety lock and trigger button is on, the output signal of the follow-up port will be sent out.
2.1.4 Controller signal interface 2
Signal interface 2 uses 6P interface, air valve and wire feeding are related
① Reserved feet for feet
② Feet reserved for feet
The ③/④ pin is the output of the air valve 24, and the control board has built-in relays, which can be directly connected to the air valve
The ⑤/⑥ pin is the wire feeder signal line, connected to the signal port of the wire feeder, regardless of positive or negative
2.1.5 Controller signal interface 3
Signal interface 3 uses 7P interface, laser related
① The pin is the laser alarm signal input +, if it needs to be enabled (wiring is required), please set the alarm level to high in the background, otherwise it is low
②The pin is enable +, connected to the enable of the laser
③The number pin is 24V output, directly output 24V+ after power on
④ The pin is the common ground (the reference ground of pin 1/2/3/5)
⑤Pin is analog + output, analog given
⑥Pin is PWM modulation signal
⑦Pin is PWM+ modulation signal
2.2 Controller wiring diagram
2.3 Optical fiber input interface
The welding head of the handheld laser welding machine is suitable for the vast majority of industrial laser welding machine generators. Commonly used optical fiber connectors include PG, Raycus, Chuangxin, Feibo, Tottenham, Japter, Caplin, etc. The optics must be kept clean and all dust must be removed before use. When the fiber is inserted, the cutting head must be rotated 90 degrees to be placed horizontally, and the fiber must be protected from dust from falling into the interface.
2.4 Shielding gas and water cooler interface
The water pipe and air pipe interface can be installed with a hose with an outer diameter of 6M and an inner diameter of 4M. The middle is the air inlet, and the two sides are the water inlet and outlet pipes (regardless of the direction of the inlet and outlet). As shown in the figure below, the water channel
part of the sub-welding joint of the cooling system and the water channel part of the optical fiber head are connected in series, as shown in the figure below.
2.5 The connection interface between the welding gun and the control box
The welding gun and the control box are connected by three wires, including: two wires for the motor power wire, five wires for the motor signal wire, three wires for the safety lock and trigger button
The motor power/signal wires (two black) are directly connected to the motor part of the welding head and can be disassembled (two options are available: )
1. Open the motor cover and side plate of the handheld welding torch
2. Open the control box and both
The safety lock and trigger button three-core wires use detachable aviation plugs: safety lock and button wires, of which 1 is blue, 2 is black, and 3 is brown (connected to 6/7/8 pins of signal interface 1, see the wiring settings of the control box above for details).
3. Control panel and operation guide
3.1 Operation overview and operation guide
The series of operation panels are mainly composed of touch screen and control box. The touch operation interface mainly sets, monitors and other parts
3.1.1 Touch screen operation main screen
①In this interface, you can see the current process parameters and instant alarm information ②The laser is enabled and the red light is ON when it is turned on
③The safety lock is usually gray, when the welding head touches the workpiece, it turns green and can be processed
④ Welding mode selection, the default is continuous. When it is set to spot welding, it can emit light intermittently for spot welding operation, which is convenient to control the spot welding time due to human error. This function needs to be set on demand (V3.3 version is the above function) ①This interface can see the current process parameters and instant alarm information
②The laser is enabled and the red light is ON when it is turned on
③The safety lock is usually gray, when the welding head touches the workpiece, it turns green and can be processed
④ Welding mode selection, the default is continuous. When it is set to spot welding, it can emit light intermittently for spot welding operation, which is convenient to control the spot welding time due to human error. This function needs to be set as needed (V3.3 version is the above function)
④Wire feeding delay compensation is the advance time of wire feeding relative to the light output signal, which can be used with the retraction function
⑤The maximum temperature alarm threshold is 70°C, when the value is set to 0, no temperature alarm will be detected
⑥Scan correction coefficient range 0.01~4, coefficient target line width/measurement line width: generally 1.2
⑦Laser center offset -3^3m, decrease to the left, increase to the right
⑧The alarm level signal is the default, and the shielded alarm can be directly changed to the corresponding level detection (no wiring required)
⑨The spot welding duration is the light emission time after the trigger is pulled, that is, even if the button is released, the light will still be emitted according to the light emission time (V3.3 version is the above function)
⑩The spot welding interval is the light-off time between two spot weldings after the trigger button is pulled (V3.3 and above functions)
Click the HLP button on the upper right to get more explanations of relevant parameters
3.14 Monitoring main interface
This interface displays the status of each detection signal and device information
①Click on the device authorization to enter the authorized usage time interface, after entering the password, the system can be authorized to use the authorized encryption and decryption methods
②The system version is divided into three groups, the first group is the hardware version, the second group is the hardware software version, and the third group is the display version
4. Maintenance
4.1 How to maintain and replace the protective lens
①Before operation, wash your hands with detergent and dry them, then wipe your hands again with cotton sticky alcohol
②Remove the screws of the protective lens compartment cover in a relatively dust-free place, pull out the protective lens bracket, protect it well (cover it with masking paper), and check the protective lens (if there is obvious burning point on the surface of the protective lens, it should be replaced directly.)
③ Then check the white power seal ring under the protective lens. (If the energy storage seal is scratched or deformed, it cannot be used and must be replaced immediately
④ Wipe the inside of the bin opening and the bin cover with a cotton ball dipped in alcohol, quickly insert the protective mirror bracket into the protective mirror bin, and lock the screw
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④. Minor left and right deviation can be set by setting the laser center offset of the panel
5. Common exception handling
5.1. Minimize the laser / water cooler / air pressure alarm
① If the above alarm occurs without using the alarm signal, please change the alarm level
② If the above alarm occurs when the alarm signal is used, check whether the alarm of the corresponding equipment or the high and low levels of the alarm signal are set incorrectly
5.2. The screen is off/no response to clicking
①The screen is not bright. If the controller is powered on (the fan is running), check whether the four-core wire between the controller and the screen is connected correctly, and whether the 24V voltage of pin 1 and pin 4 is normal. ②If the click fails during normal use, check whether the temperature of the whole machine is too high
③Click and cannot input, check whether the four-core wire between the controller and the screen is connected correctly, and whether the 2nd and 3rd pins are normal, see 2.1.2 Controller LCD screen terminal for details
④ If there is no response to clicking on the newly installed device, it may be that the system version does not match. Just re-flash the program. Please ask our company for the SD card.
5.3. The laser welding machine does not emit light
①The monitoring interface can exclude other alarms. When the welding head touches the workpiece to be processed, the safe lock is displayed in green, and it can be processed at this time. If it is gray,
Then check whether the connection of the safety lock is normal
That is, check that all ready signals are normal
Usually, the laser fails to emit light while feeding the wire, or there is a problem with the wiring. If there is no gas and no wire feeding, it may be a problem with the preparation signal. For details, see: 2.1.3 Controller signal interface 1
5.4. Light suddenly stops during processing
The monitoring interface checks whether the safety lock and other alarms are normal, and checks whether the temperature exceeds the temperature alarm threshold
5.5. Red light bias
See 4.2 Laser center adjustment method for details
Laser welding machine three-phase power wiring reference
Note: Two-phase or three-phase power depends on the power supply required by the laser and chiller, not the wiring harness. The
instruction manual for the wire feeder of the handheld laser welding machine is as follows:
1. Overview
This manual covers the basic installation, factory settings, operation and maintenance services of this laser welding machine welding wire feeding product. This product covers the self-developing control system, and sets the function of pulling back and making up wires. This product can be adapted to various hand-held welding wire feeding systems.
1.1 Operating environment and parameters
Power supply voltage (V)220±10%VAC50/60Hz
Placed in a flat environment, free from vibration and shock
Working environment temperature (°C) 10~40
Working environment humidity (%)<70
Maximum support wire weight 25KG
The maximum support wire feeding wire diameter is 2.0mm
1.2 Attention information
1) Ensure reliable grounding before power supply
2) The wire feed roller matches the wire warp and corresponds to the wire feed tube
3) The wire feeding tube should not be twisted
. 2. Installation
2.1 General definition of circuit wiring
2.1.1 The whole machine provides a three-core aviation plug, which is connected to the three-core aviation plug at the end of the wire feeder to provide 220V power supply
2.1.2 The whole machine provides a two-core aviation plug, which is connected to the wire feeding port of the control system and provides a wire feeding signal (passive contact, short connection means wire feeding)
2.2 Installation of welding wire reel
1. The welding wire is ordinary welding wire, the common ones are 5KG-30KG and can be installed, but do not use flux-cored welding wire
2 Adjust the strength of the roller through the inner hexagon, so that it is not too tight or too loose, and there is no jamming when feeding the wire (usually no need to adjust)
3 After adjustment, cover the cap
5. Operation panel of wire feeder for handheld laser welding machine
1. The value on the home page shows the wire feeding speed, which can be adjusted by pressing the up and down keys. Please keep it running when using it.
2 Manual wire feeding: After pressing and holding, the wire feeder starts to feed wire, and the manual wire feeding speed depends on the settings in the background
3 Manual retraction: After pressing and holding, the wire feeder starts to retract, and the manual retraction speed depends on the background settings
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