Transcript
FiberCUT ™ RAc Operation Manual
WARNING WORKING AROUND HIGH-POWERED LASERS CAN BE DANGEROUS
COPYRIGHT ©2016 Laser Mechanisms, Inc. All rights reserved. No part of this publication may be reproduced in any form, or by any means without the prior written permission of Laser Mechanisms, Inc.
Laser Mechanisms, Inc.’s cutting heads must be operated with the cutting head interlock switch connected. The switch must be CLOSED when the head is properly attached. In the event of a crash and the cutting head becoming dislodged from its normal operating position, the switch must be OPEN. This interlock switch must be connected in a circuit in such a way that it will immediately turn off the laser and stop all machine motion. Check the wiring diagrams for your system.
PRODUCT WARRANTY Laser Mechanisms, Inc. warrants this product against defects in material and workmanship for a period of one year from the date of shipment from Laser Mechanisms Inc. or an authorized distributor. During the warranty period, Laser Mechanisms, Inc. will at its option, repair or replace products that prove to be defective.
Serious personal injury and/or equipment damage can occur if the head becomes dislodged and:
The head interlock is not connected properly.
For all products returned to Laser Mechanisms, Inc. for warranty service the customer must:
Any interlock in the Laser Mechanisms’ product or laser system is defeated.
Call Laser Mechanisms, Inc. for a Return Material Authorization (RMA) number.
Properly pack the product with the RMA number on the outside of the package. Include in the package, all cables, and all accessories shipped with the product along with a description of the problem.
Prepay shipping charges to Laser Mechanisms, Inc.
Insure the shipment in case of loss or damage. Laser Mechanisms, Inc. will not accept any liability in case of damage or loss.
Laser Mechanisms, Inc. assumes no responsibility or liability for interlock switches or circuits and all interlocks are the sole responsibility of the purchaser of this head. It is the responsibility of the integrator or end user to install, connect and activate all interlocks in compliance with the applicable ANSI, CEN, DIN, etc. standard. All wiring should be done by personnel knowledgeable in electrical wiring and in accordance with the national and local electrical codes.
Laser Mechanisms, Inc. will pay the shipping charges, duties and taxes for the products returned to Laser Mechanisms, Inc. from outside the United States.
DISCLAIMER The information in this manual is subject to change without notice.
The foregoing warranty will not apply if damage is incurred resulting from improper or inadequate maintenance by the customer, unauthorized modifications or misuse, operation of the product outside its specifications, interlocks not connected properly, improper site preparation, parts or assemblies not supplied by Laser Mechanisms, Inc. or unauthorized repair by non-Laser Mechanisms, Inc. authorized personnel.
Laser Mechanisms, Inc. makes no warranty of any kind with regard to the material in this manual, including but not limited to, the warranties or merchantability and fitness for a particular purpose. Laser Mechanisms, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with furnishing, performance or use of this product.
For complete warranty information visit our web site at www.lasermech.com.
Corporate names and trademarks stated herein are the property of their respective companies.
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INITIAL INSPECTION
TERMS USED IN THIS MANUAL
Inspect all shipping containers for damage as soon as the device arrives. It is your responsibility, the recipient, to notify the freight company of any damage. The freight company will require you to provide the container that any goods were shipped in, all shipping documentation and a list of all damages. Photographs of the damage are helpful in settling a freight claim.
WARNING: The user could be injured if the warning is not followed.
CAUTION: The device or system could be damaged if the CAUTION is not followed.
Do not return damaged goods to the factory without a Return Material Authorization Number (RMA number).
NOTE: Clarification of a step or steps.
Although it is Laser Mechanisms, Inc.’s intent to insure you are up and running as soon as possible, damage incurred during shipment must be settled with the freight company before arranging for repairs or replacement. No return shipments will be accepted without an RMA number clearly printed on the outside of all shipping containers. Failure to follow this procedure could void any warranty coverage on your head. Call your sales engineer at Laser Mechanisms, Inc. for an RMA number.
SAFETY
Carefully remove the device from its shipping container and all packing material to avoid damage. Save all packaging material, including the sealed, padded pelican case, in the event the head requires shipping or storage. Check all items received against the packing list to verify that all the items were received. Please note the product you receive may differ slightly from the illustrations in this manual. While the drawings may differ, the basic procedures described within remain the same.
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WARNINGS: Follow all warnings in this manual.
SAFETY GLASSES: Everyone in the area where the laser is being used must wear laser safety glasses designed for the laser being used.
SECONDARY REFLECTIONS: Secondary reflections are dangerous; never expose any part of your body to a reflected laser beam.
INTERLOCKS: Interlocks are safety devices and should never be defeated.
ADJUSTMENTS: Always turn off or put the laser in standby before making any adjustments to beam delivery components.
BEAM DUCT: Never open any component of the beam duct while the laser is operating. Always turn the laser off before servicing any beam duct components.
MANUALS: Always read the instruction manuals before attempting to install or make adjustments to any beam delivery component.
FiberCUT™ RAc Operation Manual
TABLE OF CONTENTS 1
Introduction ........................................................................................................................................................1
2
Installation – Mechanicals .................................................................................................................................2 2.1 Robotic Mount ..................................................................................................................................... 2 2.2
Mounting the Cutting Head to the Robot Mount Bracket .................................................................... 2
2.3
Plumbing ............................................................................................................................................. 3 2.3.1
3
Water Cooling / Assist Gas / Purge Gas ..........................................................................3
2.4
Fiber Input ........................................................................................................................................... 4
2.5
Bundling .............................................................................................................................................. 4
2.6
Electrical Wiring .................................................................................................................................. 4
2.7
Electrical Grounding and Noise .......................................................................................................... 5
2.8
Control Box Mounting ......................................................................................................................... 5
Installation – Electrical ......................................................................................................................................7 3.1 Power (P1) .......................................................................................................................................... 7 3.2
Customer Interface (P2) ..................................................................................................................... 7
3.3
Digital Inputs ....................................................................................................................................... 8
3.4
3.5
3.3.1
Height Select Bits (HS1 – HS3) .......................................................................................8
3.3.2
Teach / Center of Travel (COT) .......................................................................................8
3.3.3
Programmable Retract Position .......................................................................................9
3.3.4
Motion Inhibit (HOLD).......................................................................................................9
3.3.5
Tip Select Bit (TSB) ..........................................................................................................9
3.3.6
Analog Input Enable (AIE) ................................................................................................9
3.3.7
Reset/Servo Disable (RST) ..............................................................................................9
3.3.8
Input Common (IN-COM) .................................................................................................9
Analog Inputs .................................................................................................................................. 10 3.4.1
Analog Input (ANALOG-IN, ANALOG-GND) ................................................................ 10
3.4.2
Analog Output (ANALOG-OUT) .................................................................................... 10
Digital Outputs ................................................................................................................................ 10 3.5.1
In-Position (IN-POS)...................................................................................................... 10
3.5.2
Retracted Position (RET-POS) ..................................................................................... 10
3.5.3
Tip Touch (TIP-TOUCH) ............................................................................................... 10
3.5.4
Crash/Fault (CRASH) .................................................................................................... 10
3.5.5
Output Common (OUT-COM) ....................................................................................... 10
3.5.6
Fault Code Status Bits................................................................................................... 11
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3.5.7
4
3.6
Interface Example ............................................................................................................................. 12
3.7
Ethernet Interface (P3) ..................................................................................................................... 13 3.7.1
Simulating Inputs (i1 – i8) .............................................................................................. 13
3.7.2
Simulate Analog Input (anlg) ......................................................................................... 13
3.7.3
Output Status (MG @OUT[n]) ....................................................................................... 14
3.7.4
Temperature Status (MG tmp1, tmp2, tmp3) ................................................................ 14
3.7.5
Inquire Analog Height Sense (MG @AN[1]) ................................................................. 14
3.7.6
Inquire Analog Head Position (MG @AN[2]) ................................................................. 14
3.7.7
Unsolicited Fault Status................................................................................................. 14
3.8
Head-Control Cable (P4) .................................................................................................................. 15
3.9
Remote I/O Options .......................................................................................................................... 15 3.9.1
EtherNet/IP .................................................................................................................... 16
3.9.2
DeviceNet ...................................................................................................................... 17
3.9.3
Profibus ......................................................................................................................... 18
3.9.4
PROFINET .................................................................................................................... 19
Operation ......................................................................................................................................................... 20 4.1 Power Up .......................................................................................................................................... 20 4.2
Sequence of Operation ..................................................................................................................... 20
4.3
Special Cases ................................................................................................................................... 22 4.3.1
4.4
4.5 5
Crash Interlock Relay (INT1, INT2) ............................................................................... 11
Starting Off the Part....................................................................................................... 22
Centering the Laser through the Tip ................................................................................................. 22 4.4.1
Centering the Beam in the Tip Orifice ........................................................................... 22
4.4.2
Centering the Beam Using the Camera System ........................................................... 23
Setting Focus to Tip Distance ........................................................................................................... 26
FiberCUT™ Monitor ........................................................................................................................................ 29 5.1 System Requirements ...................................................................................................................... 29 5.2
Installation ......................................................................................................................................... 29
5.3
Connecting ........................................................................................................................................ 30
5.4
Firmware Update and Configuration ................................................................................................. 30
5.5
Manage Connections ........................................................................................................................ 31 5.5.1
Add an Address ............................................................................................................. 31
5.5.2
Modify an Address......................................................................................................... 32
5.5.3
Reassign an Address .................................................................................................... 32
5.5.4
Rearrange Addresses ................................................................................................... 32
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5.6
Temperature Displays ....................................................................................................................... 32
5.7
Position Display ................................................................................................................................ 32
5.8
Active Standoff Display ..................................................................................................................... 33
5.9
Inputs ................................................................................................................................................ 33
5.10 Outputs ............................................................................................................................................. 33 5.11 Status Display / Fault Code History .................................................................................................. 33 5.12 Preferences ....................................................................................................................................... 33 5.13 Diagnostic View ................................................................................................................................ 34 6
Service.............................................................................................................................................................. 35 6.1 Replacing Gas Jet Nozzle Tip .......................................................................................................... 35 6.2
Tip Assembly Removal and Reinstallation ....................................................................................... 36
6.3
Cleaning Optics................................................................................................................................. 37
6.4
Changing the Cover Glass ................................................................................................................ 38
6.5
Changing the Focusing Lens Optics ................................................................................................. 39
6.6
Removing the Cutting Head from the End of the Robot ................................................................... 40
6.7
Fiber Collimator Assembly Removal and Reinstallation ................................................................... 41
6.8
Turning Mirror Removal and Reinstallation ...................................................................................... 42
6.9
Changing the Collimating Lens Cartridge or Optics ......................................................................... 43
6.10 Changing the Collimating Lens Optics ............................................................................................. 44 6.11 Motor Removal and Reinstallation .................................................................................................... 46 6.12 Dust Seal Removal and Reinstallation ............................................................................................. 49 7
Specifications .................................................................................................................................................. 51
8
Troubleshooting .............................................................................................................................................. 52
9
Appendix A – Coolant Specifications ........................................................................................................... 54
10 Appendix B – Assist Gas Specifications ...................................................................................................... 54 11 Appendix C – Beam Delivery Purging ........................................................................................................... 54 12 Appendix D – Fiber End Types ...................................................................................................................... 55 13 Appendix E – Recommended User-Serviceable Parts List ......................................................................... 56 14 Glossary ........................................................................................................................................................... 59
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1 Introduction This manual explains the steps of installing, setup, operation and service of a FiberCUT™ RAc robotic laser.
The FiberCUT™ robotic laser processing head was developed to work in the most extreme manufacturing environments. Right angle entry of all connections, including fiber, provides tight access to parts, easy cable routing and stress reduction on the input fiber. The FiberCUT™ is made up of four main subassemblies. See Figure 1.
The robotic mount
The fiber collimator assembly
The drive mechanism
The tip retainer assembly
See Figure 2 for the path of the laser beam through the FiberCUT™. The robotic mount connects the cutting head to the robot, often through an optional collision sensing device. The fiber collimator unit uses a doublet collimating lens to gather the laser light and collimate it after it leaves the fiber optic cable.
Figure 1
A collimator focal length of 100mm is standard (other focal lengths are available if the application requires).
The laser beam then reflects 90° off a turning mirror to the final focusing lens which focuses the beam through the orifice of the tip. The drive assembly provides the motion system that allows the tip to track the surface of the part and maintain laser focus.
The drive system has 17mm of travel and is controlled by a patented drive system which provides smooth, linear motion.
The tip retainer assembly contains the final focusing lens and a cover glass that protects the lens from dirt and debris. The lens housing is threaded into the tip assembly.
The tip threads into the end of the tip retainer and controls gas flow to the work piece.
The tip retainer assembly also provides the electrical feedback to maintain a constant gap between the tip and part.
The tip retainer assembly comes in various focal lengths and configurations, allowing the end user to optimize the cutting head configuration.
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Figure 2
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2 Installation – Mechanicals 2.2 Mounting the Cutting Head to the Robot Mount Bracket
2.1 Robotic Mount The robotic mount attaches to the robot and can provide optional collision sensing to protect the cutting head during a crash. See Figure 3. The collision sensor mounts to the robot using an adapter. The appropriate hardware will be provided with the cutting head determined at the time of sale.
The cutting head is secured to the robotic mount with four M5 SHCS and is positioned on two 5mm dowel pins. The robot mount bracket has multiple hole patterns which allow the end user to rotate the head in 30° increments. See Figure 4. This set-up provides the flexibility to orient the cables to best suit the application. It is up to the end user to identify the best location for a particular application.
Figure 3 The optional collision sensor (sold separately as part number PLCPD0084) is a pneumatic device.
The sensor requires 6mm OD hose.
The recommended operating pressure for the collision sensor is 1 BAR, but can vary depending on application.
The hoses need to be suitable for robotic applications.
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Figure 4
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2.3 Plumbing
o
When the gas source is less than 25 feet (7.5 meters) away from the FiberCUT™ head, route 8 mm OD hose between the gas source and the proportional valve.
o
When the gas source is over 25 feet (7.5 meters) away from the FiberCUT™ head, route 3/8 inch OD (minimum) hose between the gas source and the proportional valve.
o
Specifications for assist gas can be found in Appendix B.
o
The assist gas line must be rated higher than the maximum expected pressure.
o
For systems that use oxygen (O2), verify that valves, fittings, and hoses are compatible.
2.3.1 Water Cooling / Assist Gas / Purge Gas All lines must be suitable for robotic applications and are supplied by the integrator. See Figure 5 for line locations.
The water cooling lines require 6mm OD hoses. Cooling specifications can be found in Appendix A.
Assist gas recommendations: o
A proportional gas valve placed within 8 feet (2.5 meters) of the FiberCUT™ head.
o
8mm OD hose between the proportional valve and the FiberCUT™ head. A short flexible hose is included with the cutting head and should not be removed unless replaced with an equivalent unit.
The purge gas line requires 6mm OD hose. A particle filter and two short flexible hoses are included with the cutting head and should not be removed unless replaced with equivalent units. Specifications for purge gas can be found in Appendix C.
Figure 5
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2.6 Electrical Wiring 2.4 Fiber Input
There can be two electrical wires connected to the cutting head. See Figure 6.
The fiber input is where the fiber optic cable plugs into the cutting head. See Figure 5. There are several industrial standard styles of fibers ends (QBH, QD/LLK-D, LCA, QS/LLK-B, HCL-8 & PIPA). See Appendix D for sample images of each. Each of these fibers has a unique method of securing it to the fiber input adapter. Refer to the fiber manufacturer’s information for specific instructions.
One is the communication cable between the cutting head and the control box (PLCAB0489).
The other is the optional collision sensor cable that is plugged into the robot system interlock (PLCAB0488).
2.5 Bundling As in any robotic application, cables need to be bundled in a manner which allows complete tool movement without pinching or pulling of the cables. The FiberCUT™ head was designed so that all cables input in the same location – allowing a sleek, easy-to-manage bundle. Cabling should not be tethered to the fiber input connector or the fiber optic cable. See Figure 5. The manner in which the cables are bundled is one of the keys to having a successful robotic cutting cell. The end user is responsible for documenting and training personnel on the best bundling methods for their application.
Figure 6
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2.7 Electrical Grounding and Noise
2.8 Control Box Mounting
The capacitive sensing circuitry contained in the FiberCUT™ cutting head measures minute changes in electrical capacitance between the tip and earth-ground to determine tip-to-part standoff distance. In order for this circuit to function properly the part and the cutting head need to be connected to a good earth ground.
The important things to consider when mounting the control box are:
Ideally the ground should be established from a ground rod, approximately 2 meters in length driven into the ground located near the base of the robot.
A large gauge (1.6mm diameter or larger) ground wire should be run from the ground rod to the part.
Run a separate wire from the ground rod to the mount of the FiberCUT™ at the end of the robot See Figure 7.
Clearance to attach connectors
Clearance to open the control box door
Standard cable length is 15 meters
Easy access for maintenance.
Mounting such that debris from the process is not directed at the controller box.
Mounting in an area where there are no water leaks or oils from hydraulic presses.
The control box mounting pattern is illustrated in Figure 8.
Mounting screw heads are located inside the control box.
Figure 7 Electrical noise can create sensing issues. Large electric motors, arc welders and other devices may be a source of significant electrical noise. In order to eliminate this noise it may be necessary to connect a ground wire to the chassis of any such device near the process.
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Figure 8
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The control box door clearance dimensions are illustrated in Figure 10.
The control box mounting clearance envelope dimensions are illustrated in Figure 9.
Figure 10
Figure 9
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3 Installation – Electrical
3.2 Customer Interface (P2) PIN P2-1 P2-2 P2-3 P2-4 P2-5 P2-6 P2-7 P2-8
Figure 11
P2-9 P2-10
3.1 Power (P1)
P2-11
Specifications: 85 to 264VAC, 50/60Hz, 6A
P2-12 P2-13 P2-14 P2-15 P2-16 P2-17 P2-18 P2-19
Figure 12
P2-20
Power to the FiberCUT™ controller is connected using P1 (4-pin connector) on the bottom left side of the control box. A power cord is included with the system, however alteration of this connection may be preferred based on specific installation requirements.
P2-21 P2-22 P2-23
PIN 1 2 Ground
DESCRIPTION Hot Neutral Ground
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P2-24
7
NAME
DESCRIPTION INPUTS Height Select Bit 1 Input-1 (HS1) (LSB) Input-2 (HS2) Height Select Bit 2 Height Select Bit 3 Input-3 (HS3) (MSB) Input-4 (COT) Teach/Center of Travel Input-5 Motion Inhibit/Hold (HOLD) Input-6 (TSB) Tip Select Bit Input-7 (AIE) Analog Input Enable Input-8 (RST) Reset Input Common (IN- Input Common COM) ANALOG-IN Stand-off Height Select ANALOGAnalog Ground GND OUTPUTS ANALOGConfigurable Output OUT Voltage Output-1 (INIn-Position POS) Output-2 Retracted Position (RET-POS) Output-3 Tip Touch (Tip Touch) Output-4 Crash/Fault Active (Crash) Output-5 Status Code 1 (LSB) (STAT1) Output-6 Status Code 2 (STAT2) Output-7 Status Code 3 (STAT3) Output-8 Status Code 4 (MSB) (STAT4) Output +V-Sourcing, 0VCommon Sinking (OUT-COM) N/C N/C Crash Interlock Relay INT1 N/O, 60V, .5A Max Crash Interlock Relay INT2 N/O, 60V, .5A Max
FiberCUT™ RAc Operation Manual
3.3.2 Teach / Center of Travel (COT) The COT input sets the head in the fixed center of travel position. When teaching the motion system path, it is preferable to have the FiberCUT™ head in the COT position. Figure 13
At the COT position, the label on the telescoping tube will have half of the green section exposed. See Figure 14.
3.3 Digital Inputs
Specifications: 5 to 24VDC, 10mA at 24V
The inputs are configurable for connection to either sourcing or sinking outputs depending on the connection made to the input common. 3.3.1 Height Select Bits (HS1 – HS3) The three discrete height select bits activate seven standoff heights. When all height select bits are off, the head will return to its retracted position. Note: The height select bits are only operative if the analog input enable (AIE) is off.
The • symbol indicates ON. HS1
HS2
HS3
• •
• •
• •
• •
• • • •
STANDOFF HEIGHT 0.5mm 0.75mm 1.0mm 1.25mm 1.5mm 1.75mm 2.0mm Head Retracted
Figure 14
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COT has precedence over HS1, HS2 and HS3.
FiberCUT™ RAc Operation Manual
3.3.3 Programmable Retract Position The FiberCUT™ controller has the ability to position the head at seven different retracted positions. To enable this feature, click the check box for Prog. Retract Positions in the Preferences of FiberCUT™ Monitor. See Section 5.12.
HS3
• • •
• •
• •
•
• • • •
See Section 4.3 for more details.
3.3.6 Analog Input Enable (AIE)
PROG. RETRACT POSITION -8.5mm (COT) -7.5mm -6.5mm -5.5mm -4.5mm -3.5mm -2.5mm -1.5mm
When AIE is active, the standoff height will be controlled by ANALOGIN.
With AIE inactive, the standoff height is set by HS1, HS2 and HS3.
If AIE, HS1, HS2 and HS3 are off, the head will retract unless COT or HOLD is active.
3.3.7 Reset/Servo Disable (RST)
When the head has reached the programmable retract position, the RETPOS (Retracted Position) output will become active. This feature can reduce cycle time by minimizing the amount of travel that the head has to move inbetween cuts. Note: The FiberCUT™ controller does not perform a height sensor calibration when using this feature.
RST allows the head to be reset if a fault occurs.
When RST is activated, the Crash output will be active and the FiberCUT™ will fully extend. Once RST is deactivated, the FiberCUT™ will fully retract and recalibrate. If RST is held active, the FiberCUT™ servo motor will be disabled and the head will fully extend.
3.3.8 Input Common (IN-COM)
3.3.4 Motion Inhibit (HOLD) The HOLD input holds the head at the current position regardless of the measured standoff height.
The TSB input allowed selection of the type of tip installed on the head in early controller versions. This functionality is replaced by the FiberCUT™ Controller Firmware Update PC software. The tip select bit should remain off unless otherwise instructed. See Section 5.4 for more information.
The • symbol indicates ON. HS2
HOLD has precedence over HS1, HS2, HS3 and COT.
3.3.5 Tip Select Bit (TSB)
Once enabled, this feature can be activated by simultaneously activating the COT (Center of Travel) and a combination of Height Select Bits.
HS1
Connect +V to IN-COM when the inputs are connected to sinking (active low) outputs.
Connect 0V to IN-COM when connecting to sourcing (active high) outputs.
HOLD is useful when the cutting path must start in a location that is not over the work piece.
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3.4 Analog Inputs
3.5 Digital Outputs
3.4.1 Analog Input (ANALOG-IN, ANALOG-GND)
Specifications: 5 to 24VDC, 250mA per output All outputs are configurable for sourcing or sinking depending on the connection made to OUT-COM.
0 to 5VDC (input range)
Selects standoff height. Working range is 1V to 4V (1V=>0.5mm; 4V=>2.0mm).
3.5.1 In-Position (IN-POS)
3.4.2 Analog Output (ANALOG-OUT)
0 to 5VDC
There are 5 different output options available. See Section 5.12 for setting the preferences.
IN-POS indicates that the tip is within range of the selected standoff height. Typically IN-POS provides a handshake back to the motion system that the tip has reached the part and is ready to begin processing. 3.5.2 Retracted Position (RET-POS)
1. HSU Voltage: A non-linear voltage that represents the stand-off distance between the tip and work piece.
RET-POS indicates that the head is at the retracted position. Typically RETPOS provides feedback to the motion system that the head is parked at the retracted position.
2. Linear Pot Voltage: A linear voltage that represents the physical position of the FiberCUT™ drives mechanism.
3.5.3 Tip Touch (TIP-TOUCH) The TIP-TOUCH signal indicates that the tip has electrically contacted the part or object. This can occur during normal processing and does not produce a fault.
3. Electronics Temperature: A voltage indicating the approximate temperature of the electronics contained in the head (°C = V x 10).
3.5.4 Crash/Fault (CRASH)
4. Collimator/Mirror Block Temperature: A voltage indicating the approximate temperature of (1) The FiberCUT™ ST collimator OR (2) The FiberCUT™ RA or RAc mirror block (°C = V x 10).
CRASH indicates that the head is currently in a crash or fault condition. Check the STAT1 – STAT4 for information about the crash. 3.5.5 Output Common (OUT-COM)
5. Focus Lens/Nozzle Assembly Temperature: A voltage indicating the approximate temperature of the FiberCUT™ nozzle area – cover glass and focus lens. (°C = V x 10).
Connect +V to OUT-COM for sourcing (active high) outputs
Connect 0V to OUT-COM for sinking (active low) outputs.
The temperature reading is NOT for the nozzle assembly alone.
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3.5.6 Fault Code Status Bits
STAT1
STAT2
STAT3
STAT4
• •
• •
•
• • •
•
•
• •
• •
• •
• • •
• • •
•
• •
• •
•
•
•
• • The
STATUS CODE No Fault 1: Head Not Extended 2: Hit Retract Limit 3: Calibration Fault 4: Extending Watchdog 5: Retract Watchdog 6: Temperature Watchdog 7: Overtemp. Focus Lens and Nozzle Assembly 8: Overtemp. Collimator 9: Overtemp. Head Electronics 10: Temperature Error 11: Not Centered 12: Failed To Reach Extend Limit 13: Height Sensor Position Error 14: Hold Position Error 15: Failed To Retract
* Automatic Sleep Mode
While in sleep mode the FiberCUT™ will disable its servo motor and the head will fully extend. All of the status bits (STAT1, STAT2, STAT3 and STAT4) will be active but the crash output will remain inactive indicating that the FiberCUT™ has entered sleep mode.
Set up automatic sleep mode according to Section 5.12.
3.5.7 Crash Interlock Relay (INT1, INT2)
Solid State Relay Rating: 500mA at 0-60VDC, 0-48VAC
A solid-state relay opens to indicate a fault or crash condition on the cutting head.
*
• symbol indicates ON.
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3.6 Interface Example The interface allows control and feedback of all the FiberCUT™ operations.
Interface Figure 15
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3.7 Ethernet Interface (P3)
3.7.1 Simulating Inputs (i1 – i8)
The Ethernet port provides a means of interfacing to the FiberCUT™ controller with all of the capabilities of the discrete I/O with the addition of fault descriptions. Connect the Ethernet port (P3) to your motion system using a crossover or null modem Ethernet cable, or to a network hub by a straight through Ethernet cable. The controller has been assigned the IP Address 169.254.99.12. A standard Windows Telnet session can connect to the controller. See Figure 16.
The variables i1 – i8 are used to simulate the discrete inputs by assigning the variables a value of 1 or 0. Examples: i1=0; i2=0; i3=1 - Sets the standoff height to 1.25mm. i5=1 - Turns on motion inhibit. i5=0 - Turns off motion inhibit.
Note: The commands and inquiries interact directly with the program running on the LM/Galil controller. Unintentional alteration of the program may result if improper instructions are given. Care should be taken that the commands to the controller are accurate.
3.7.2 Simulate Analog Input (anlg) The variable anlg is used to simulate the external analog input by assigning values to the variable using the same rules as the external analog input. The standoff height is set with a value of 1 – 4, which gives a corresponding standoff value of 0.5mm to 2.0mm. Examples: i7=1 - Activates external analog input.
(Refer to Galil RIO-47IXO User Manual for additional information.)
anlg=2.5 - Sets the standoff height to 1.25mm.
Figure 16
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3.7.3 Output Status (MG @OUT[n])
3.7.5 Inquire Analog Height Sense (MG @AN[1])
The status of any of the discrete outputs can be inquired by sending the MG @OUT[n] command where n indicates the output in question from 0 to 15. A response of: 1.0000 indicates that the output is on while a response of: 0.0000 indicates that the output is off. Using n values from 0-7 correspond with outputs 1-8.
The value of the analog tip height sense signal can be monitored by the command MG @AN[1]. The value given back is a highly non-linear value from 0 to 5 indicating a tip standoff height of 0 to ~10mm. Examples: MG @AN[1] - Inquire the analog standoff value.
Examples: MG @OUT[0] - Inquire the status of INPOS.
: 3.2134 - Tip has ~1mm standoff.
: 1.0000 – IN-POS is active.
3.7.6 Inquire Analog Head Position (MG @AN[2])
MG @OUT[13] - Inquire the status of the crash interlock
The value of the analog position feedback from fully extended (~0) to fully retracted (~5).
: 0.0000 - Interlock is open. 3.7.4 Temperature Status (MG tmp1, tmp2, tmp3)
Examples: MG @AN[2] - Inquire the analog head position.
The status of the three temperature sensors inside the head can be inquired using this command. The returned value is in degrees Celsius. The three temperatures (tmp1, tmp2, tmp3) correspond to sensors located on the turning mirror block, nozzle assembly and the head electronics respectively.
: 2.5872 - Reply indicating head is near center. 3.7.7 Unsolicited Fault Status When a fault occurs, the controller sends a description of the fault. This action is triggered by the fault, thus no inquiries are required.
Examples: MG tmp1, tmp2, tmp3 - Inquire the status of all 3 temperatures.
Examples: 2: Hit Retract Limit.
: 25.3245 28.6532 33.2313 -Temperature of sensors.
7: Overtemp Mirror.
MG tmp2 - Inquire temperature of the nozzle.
11: Not Centered.
: 35.2834 - Temperature is 35.2834 deg. C.
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3.8 Head-Control Cable (P4)
3.9 Remote I/O Options
A straight through 14-conductor cable (PLCAB0489) connects the FiberCUT™ head to the controller. See Figure 17. This cable should be routed away from high power and high voltage wires to prevent interference.
The remote I/O option in the FiberCUT™ controller simplifies the hardware integration into the laser processing cell. Instead of using the discrete I/O connections in the customer I/O connector, the integration can consist of a relatively simple cable. Four different protocols are available to support most industrial networks.
This cable is a high-flex cable designed for robotic applications, but minimizing the amount of movement and flexing that the cable is exposed to can increase the life of the cable.
Device configuration files (EDS or GSD) and supplemental manuals are available for download from the FiberCUT™ Updates web page:
http://www.lasermech.com/fibercutupdates.asp
All remote I/O options include the digital inputs and digital outputs shown below.
Digital Inputs
Figure 17
Digital Outputs
BIT 7
RESET
BIT 7
STAT4
BIT 6
AIE
BIT 6
STAT3
BIT 5
TSB
BIT 5
STAT2
BIT 4
HOLD
BIT 4
STAT1
BIT 3
COT
BIT 3
CRASH
BIT 2
HS3
BIT 2
TIP-TOUCH
BIT 1
HS2
BIT 1
RET-POS
BIT 0
HS1
BIT 0
IN-POS
Some controllers also include analog voltage and temperature readings for monitoring purposes. Voltages are reported as 12-bit numbers, where 04095 = 0-5V. Temperatures are reported as hundredths of degrees Celsius, where 0-7000 = 0.00-70.00°C. The (4) sections that follow provide specific data mappings for each controller configuration.
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3.9.1 EtherNet/IP
PLCSA0046 Configuration The FiberCUT™ controller with an external power switch consists of a HMS Industrial Networks Anybus IC EIP module and Interconnect Board.
The connection to the EtherNet/IP uses an RJ45 jack in the FiberCUT™ controller. The EtherNet/IP should not be confused with the computer Ethernet interface used for FiberCUT™ Monitor. See Figure 18.
The IP Address is set using the rotary switches S1 (x10) and S2 (x1) on the Interconnect Board to addresses ranging from 192.168.1.1192.168.1.99 on Subnet 255.255.255.0. Selecting a value of 00 allows the IP Address to be configured using Fieldbus Settings on the ™ Preferences page of FiberCUT Monitor and is set to DHCP by default. See Section 5.12. PARAMETER Input Size (Bytes) Output Size (Bytes) Configuration Size (Bytes) Input Instance Output Instance Configuration Instance I/O Data Type
Figure 18 PLCSA0023 Configuration The FiberCUT™ controller without an external power switch consists of an Allen Bradley 1734-AENT Point I/O module.
BYTE
The IP Address is set using the switches on the module or software provided by Allen Bradley. Refer to Allen Bradley Publication ENETUM001N-EN-P for more information. PARAMETER Input Size (Bytes) Output Size (Bytes) Configuration Size (Bytes) Input Instance Output Instance Configuration Instance I/O Data Type BYTE 1-10 11 1 2 3
1 2-3 4-5 6-7 8-9 10-11
VALUE 11 3 0 101 100 102 SINT
1
VALUE 11 1 0 100 150 1 SINT
DESCRIPTION INPUTS Digital Outputs Analog Height Sense Analog Head Position Nozzle Temperature Mirror Block Temperature Electronics Temperature OUTPUTS Digital Inputs
DESCRIPTION INPUTS Not Used Digital Outputs OUTPUTS Not Used Digital Inputs Not Used
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3.9.2 DeviceNet PLCSA0044 Configuration
The connection to the DeviceNet I/O uses a 5-pin micro connector located in the bottom corner of the control box. See Figure 19.
The FiberCUT™ controller with an external power switch consists of a HMS Industrial Networks Anybus IC DEV module and Interconnect Board. The Node Address is set using the rotary switches S1 (x10) and S2 (x1) on the Interconnect Board to addresses ranging from 01-63. Selecting a value of 00 allows the Node Address to be configured using Fieldbus Settings on the Preferences page of FiberCUT™ Monitor. See Section 5.12. A termination resistor is fitted on the Interconnect Board and is controlled using switch S5.
Figure 19 PLCSA0015 Configuration The FiberCUT™ controller without an external power switch consists of an Allen Bradley 1734-ADN Point I/O module that is preconfigured to appear on Node 12. Refer to Allen Bradley Publication 1734-UM002CEN-P for more information on configuring the module.
1-3 4 1-2 3
If this device is not the last node in the system, it is necessary to switch S5 to OFF.
1 2-3 4-5 6-7 8-9 10-11
If this device is not the last node in the system, it is necessary to remove this resistor.
BYTE
BYTE
If this device is the last node in the system, then the terminating resistor remains in place.
PARAMETER Input Size (Bytes) Output Size (Bytes) Baud Rate
If this device is the last node in the system, then S5 should be ON.
PARAMETER Input Size (Bytes) Output Size (Bytes) Baud Rate
A termination resistor is fitted on the terminal block of the I/O module in the FiberCUT™ controller. (S5 on new controllers).
VALUE 4 3 125K
1
VALUE 11 1 125K
DESCRIPTION INPUTS Digital Outputs Analog Height Sense Analog Head Position Nozzle Temperature Mirror Block Temperature Electronics Temperature OUTPUTS Digital Inputs
DESCRIPTION INPUTS Not Used Digital Outputs OUTPUTS Not Used Digital Inputs
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PLCSA0044 Configuration 3.9.3 Profibus
The FiberCUT™ controller with an external power switch consists of a HMS Industrial Networks Anybus IC PDP module and Interconnect Board.
The connection to the Profibus I/O uses a 5-pin micro connector located on the bottom of the control box. See Figure 20.
The Node Address are set using the rotary switches S1 (x10) and S2 (x1) on the Interconnect Board to addresses ranging from 01-99. Selecting a value of 00 allows the Node Address to be configured up to 126 using Fieldbus Settings on the Preferences page of FiberCUT™ Monitor. See Section 5.12. A termination switch is located on the Interconnect Board labeled S5. The FiberCUT™ controller is shipped with this switch in the OFF position.
Figure 20 PLCSA0017 Configuration The FiberCUT™ controller without an external power switch consists of an Allen Bradley 1734-APB Point I/O module that is preconfigured to appear on Node 12. Refer to Allen Bradley Publication 1734-UM005BEN-P for more information on configuring the module.
If this device is the last node in the system, then the termination switch remains OFF.
If this device is not the last node in the system, it is necessary to turn the terminating switch ON.
PARAMETER Input Size (Bytes) Output Size (Bytes)
SLOT
DESCRIPTION
1 2
Digital Inputs Digital Outputs
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If this device is the last node in the system, then the termination switch remains OFF.
If this device is not the last node in the system, it is necessary to turn the terminating switch ON.
PARAMETER Input Size (Bytes) Output Size (Bytes)
A termination switch is located on the 9-pin connector of the Profibus module. The FiberCUT™ controller is shipped with this switch in the OFF position.
SLOT
DESCRIPTION
1 2 3 4 5 6 7
Digital Inputs Digital Outputs Analog Height Sense Analog Head Position Nozzle Temperature Mirror Block Temperature Electronics Temperature
VALUE 11 1 MODULE TYPE Output 1 byte Input 1 byte Input 2 byte Input 2 byte Input 2 byte Input 2 byte Input 2 byte
VALUE 1 1 MODULE TYPE 1734-OB8 1734-IB8
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3.9.4 PROFINET The connection to PROFINET uses an RJ45 jack located in the FiberCUT™ controller. The PROFINET jack should not be confused with the computer Ethernet interface used for FiberCUT™ Monitor. See Figure 21.
SLOT
DESCRIPTION
1
Digital Inputs
2
Digital Outputs
3
Analog Height Sense
4
Analog Head Position
5
Nozzle Temperature
6 7
Mirror Block Temperature Electronics Temperature
MODULE TYPE Output 001 byte Input 001 byte Input 002 bytes Input 002 bytes Input 002 bytes Input 002 bytes Input 002 bytes
Figure 21 The FiberCUT™ controller consists of a HMS Industrial Networks Anybus IC PRT module and Interconnect Board. The customer must configure the PROFINET Master to recognize this slave device and map the data correctly. Consult your system manufacturer for specific instructions on how to configure slave devices. Object Name: Anybus-IC PRT / RT Standard Default Device Name: ABIC-PRT
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4 Operation
1. Home Position The COT input can be on or off depending on the desired sequence. If you are uncertain, leave COT on.
4.1 Power Up Prior to applying power to the controller verify: 1. The head is connected to the control with the head-control cable.
Prior to moving from the home position, it is preferable to command the head to go to COT, if it is not already at COT, followed by retract.
This sequence recalibrates the height sensor compensating for any variations in temperature, humidity, tip changes, or any other changes that may have occurred.
If COT is activated (on), automatic sleep mode is deactivated (off).
2. The remote interface to the head is connected and powered on. 3. The head is mounted securely with the nozzle pointed down. 4. The head must be allowed to fully extend prior to applying power. This is essential. After power is applied, the controller: 1. Establishes all of the head positions, such as center-position and retractposition, based on the fully extended position.
It is recommended that FiberCUT™ is not left idle for extended periods of time. Doing so may degrade the life of the motor.
2. Then commands the head to go to the retracted position.
Make sure the head is positioned away from any objects.
3. Once retracted, calibrates the height sensor.
Do not touch the tip while the head is retracting, as this affects the calibration of the height sensor.
FiberCUT™ controller software SW0012 Rev 22 or greater includes a way of powering off the motor by holding the Reset input active. o
The robot controller should activate Reset if the head is idle for more than 10 minutes.
o
While Reset is active the FiberCUT™ head will fully extend and the controller will indicate a crash condition.
o
When the robot deactivates Reset, the FiberCUT™ head will fully retract and clear the crash condition.
The power-up sequence takes a few seconds to complete. The head is now ready for operation.
4.2 Sequence of Operation Warning: It is essential that the robot monitor and verify proper operation of the FiberCUT™ head. Using the Crash, IN-POS, and RETPOS signals during processing will insure that the head is functioning correctly. Failure to monitor these signals may result in damage to the laser system.
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Sleep Mode is an alternative method of powering off the motor is included in SW0012 Rev 25 or greater and FiberCUT™ Monitor 1.6.2 or greater.
5. At End of Cut Turn off the beam, retract the head by deactivating HS1, HS2 and HS3 and turn off the assist gas.
o
If the FiberCUT™ will be idle for an extended period of time (>10 minutes), it is recommended to place it in sleep mode. In sleep mode, the servo motor will be turned off and the head will fully extend.
These actions help increase the life of the servo motor.
Summary Chart
o
o
Return to step 2 (Rapid Positioning) to move to the next feature to be cut. OR
Return to step 1 (Home Position) when the part is complete.
Steps for a cut MUST be performed in the sequence listed below. To activate the automatic sleep timer, set the Preferences according to Section 5.12.
STEP
The FiberCUT™ will only enter Sleep Mode when no inputs are active and there are no obstructions near the tip.
HEAD Retracted
01 HOME OR
2. Rapid Positioning Clearance is maximized by keeping the head in the retracted position while it is moving to a feature to be processed. Verify RET-POS is active prior to moving.
*
COT 02 RAPID POSITIONING
3. At Start Position Activate the assist gas and select a standoff height by activating a combination of HS1, HS2 and HS3.
(See Note Below) 04 PROCESSING
This signal insures that the head is properly sensing on the part.
05 END OF CUT
OTHER SETTINGS NA
COT ON/OFF HS1 OFF HS2 OFF HS3 OFF AIE OFF HOLD OFF COT OFF
NA Wait for RET ON POS
Ready to Cut
HS1 ON/OFF HS2 ON/OFF HS3 ON/OFF
Assist ON Gas Wait for IN ON POS
Cutting
NA
Beam ON
Retracted
HS1 OFF HS2 OFF HS3 OFF AIE OFF HOLD OFF
Beam OFF Assist OFF Gas Wait for RET ON POS
03 START
4. Processing Processing (turning the beam on) should begin when the IN-POS signal has been received from the FiberCUT™ controller.
Retracted
FiberCUT™ INPUTS HS1 OFF HS2 OFF HS3 OFF AIE OFF HOLD OFF OR
* When COT is activated (ON), automatic sleep mode is deactivated (OFF).
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4.3 Special Cases
4.4 Centering the Laser through the Tip
4.3.1 Starting Off the Part There may be times when the cut needs to start off the edge of the part. If the FiberCUT™ head is commanded to activate height sensing without a part present, the head will reach the extended limit and issue a crash command to the motion system.
It is essential to any laser process that the beam be centered in the gas jet tip. It is the customer’s responsibility to center the laser beam in the gas jet tip. 4.4.1 Centering the Beam in the Tip Orifice 1. Verify that the high power beam is disabled.
The following sequence can be implemented to prevent this crash condition.
2. Put a piece of translucent tape on the end of the gas jet tip.
1. Position the head so that it is located above the part, about 10mm away from the edge. That positioning ensures enough surface for sensing.
3. Turn on the laser’s internal red pointing beam and observe the position of the beam on the tape. If the beam is not centered in the tip orifice, proceed to step 4.
2. Activate the HS1, HS2 and/or HS3 to begin sensing on the part. 3. After the IN-POS signal actives, lock the head by activating HOLD.
Do not look directly into the red beam.
4. Move the head off the edge of the part. 5. Begin the laser processing by activating the assist gas and turning the beam on. Allow at least 1 second for pressurization.
Visually locating the beam inside the tip orifice can be difficult. Adequate lighting and a magnifying glass are highly recommended.
6. Turn off HOLD shortly after the head has moved onto the surface of the material.
If necessary, Laser Mechanisms offers an alternative solution. See Section 4.4.2, Centering the Beam Using the Camera System.
7. Continue to process as normal. Note: It may be necessary to end the cut in a similar method by activating HOLD prior to moving off of the part. Be sure to retract the head prior to moving to the next cut feature.
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4.4.2 Centering the Beam Using the Camera System
Tip centering is accomplished by adjusting the turning mirror. The turning mirror is located inside the main body of the cutting head.
Laser Mechanisms’ camera system is an aid in centering the beam in the tip orifice. This method uses virtual images of the beam and tip orifice on a computer screen instead of visual inspection.
4. To access the turning mirror, remove the end cap by loosening its captivated screws with a 3mm hex wrench as illustrated in Figure 22.
See the chart below to determine the appropriate camera system.
Camera System
Tip Retainer
PLFXT0212
PLTRA0360
PLFXT0213
PLTRA0369 or PLTRA0417
To use it, you will need to supply a computer and install the provided camera software package (Digital Microscope Suite). 1. Download the latest version of Digital Microscope Suite software to the computer that will be used to center the laser in the tip orifice. See http://lasermech.com/updates.asp
Figure 22 5. Use a 1/8 inch hex wrench to turn the mirror adjusting screws until the beam is centered in the tip. See Figure 23.
A PDF copy of the Celestron® Handheld Digital Microscope Instruction Manual, with more details on the features and use of the microscope, is also available on the website above.
Figure 23
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See Figure 24 for steps 2 and 3.
2. Unthread the shroud (turn it counterclockwise) to remove it from the FiberCUT™ head.
An image similar to Figure 25 will appear.
3. Install the centering tool by threading it (turning it clockwise) onto the FiberCUT™ head in the location where the shroud was.
Figure 25
If the image appears blurry, adjust it using the following (See Figure 26):
Always start with the lowest power magnification (10X).
Figure 24 4. Insert the camera cable into a USB port on the computer used to center the beam in the tip orifice.
a. Rotate the knob all the way to the left. b. Rotate the knob to the right until the image is clear.
5. Start the software by double clicking on desktop icon or the MicroCam2 icon in the Digital Microscope Suite folder. 6. Turn on the laser’s internal red pointing beam and observe the position of the beam on the computer screen.
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Figure 26
7.
If the beam is centered in the camera and tip orifice, no further adjustment is necessary.
8.
If the beam is not centered in the camera and tip orifice, adjust the beam location according to the following:
9. To access the turning mirror, remove the end cap by loosening its captivated screws with a 3mm hex wrench as illustrated in Figure 22. 10. Use a 1/8 inch hex wrench to turn the mirror adjusting screws until the beam is centered in the tip. See Figure 23.
Some trial and error may be necessary in order to center the beam in the camera and tip orifice.
11. Once the beam is centered in the tip replace the cap. See Figure 22.
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Figure 29 (on the next page) shows the nominal position of the lens holder for each tip style with the focus distance approximately 1mm outside the tip.
4.5 Setting Focus to Tip Distance This FiberCUT™ cutting head is available in four different focal lengths (75mm, 100mm, 125mm, and 150mm). It is equipped with an adjustable focus lens cell, providing an infinitely adjustable focus-to-tip setting.
Note: If focus is adjusted too far from the tip the beam may clip on the tip orifice. Consider focus location, tip orifice diameter and beam cone angle when making this adjustment.
The focus position must be customized in every application in order to achieve the optimum cut.
For mild steel applications, the focus is generally set near the top of the material.
For stainless steel and aluminum applications, the focus is generally set near the bottom of the material.
Note: Gas Jet tips and Tip Retaining Assemblies are interchangeable. The appearance of your system may be slightly different, but all of the dimensions in Figure 29 still provide a good starting point.
Figure 27 and Figure 28 show surfaces used to measure the set up distance for each focal length.
Figure 28
Figure 27
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75mm Focal Length
100mm Focal Length
125mm Focal Length Short Tip
125mm Focal Length Long Tip
150mm Focal Length
Figure 29
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Adjusting the Focus Lens Position: (see Figure 30).
If the lock nut tension is NOT set properly:
1. Remove the tip assembly as outlined in Section 6.2.
1. Pull the lens holder to remove it from the collet assembly.
2. Verify that the lock nut is tight enough so the lens holder is secured firmly in position during operation, but can still slide in and out of the collet assembly.
Adjusting the Lens Holder Tension: (see Figure 31):
If the lock nut tension is NOT set properly, proceed to Adjusting the Lens Holder Tension.
2. Tighten the lock nut and test the fit by reinserting the lens holder.
3. Slide the lens holder to the desired location into or out of the collet assembly.
The 1mm scale on the side of the lens holder can be used as a reference to make the adjustment.
The lens holder should be secured firmly in position during operation, but can still slide in and out of the collet assembly.
3. Repeat steps 1 and 2 until the lens holder is secured firmly by the collet assembly.
4. Measure and record the location of the lens holder. 5. Make sure there is no debris on either side of the focus lens.
It is possible to over tighten the lock nut.
It may be necessary to twist the lens holder to move it in and out.
4. Go to step 3 of Adjusting the Focus Lens Position.
6. See Section 6.2 to reinstall the tip assembly on the head.
Figure 30
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It is more efficient to tighten the lock nut after removing the lens holder.
Figure 31
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5 FiberCUT™ Monitor FiberCUT™ Monitor is a very useful tool for use with your FiberCUT™ head. FiberCUT™ Monitor runs on a standard PC and connects to the controller with an Ethernet cable. It provides real time monitoring of the tip standoff, head position, head temperatures and I/O of your FiberCUT™ on a single, easy-toread screen. See Figure 32 and Figure 33.
5.1 System Requirements
Windows XP or later
Screen Resolution: – Standard View: Minimum 800 x 600 – Multiple View: Minimum 1280 x 768
Ethernet Port
5.2 Installation Download the latest copy of FiberCUT™ Monitor and FiberCUT™ Controller Firmware Update (FiberCUT™ Update) from the FiberCUT™ Updates web page: http://www.lasermech.com/fibercutupdates.asp Once the compressed folders are downloaded from the web site they only need to be decompressed. 1. Right-click on each compressed folder and select Extract All.... 2. Follow the on-screen instructions to complete the decompression (extraction) of the compressed files.
Figure 32 Standard View Panel
The FiberCUT™ update (SW0012) folder will have a single executable file. The FiberCUT™ Monitor folder will have a single FiberCutMonitor.exe file and a folder named FiberCutMonitor Libs. It is important that the Libs folder remain at the same location as FiberCUT™ Monitor. The parent folder for these files can be moved and copied as needed. No license key is needed.
Figure 33 Multiple View Panel
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5.3 Connecting
5.4 Firmware Update and Configuration
All communications between FiberCUT™ Monitor and the FiberCUT™ head are made using an Ethernet cable. See Figure 34.
Prior to using FiberCUT™ Monitor for the first time, run FiberCUT™ Update (SW0012) to load the latest firmware version on the FiberCUT™ controller and to configure the controls and graphical displays to match your FiberCUT™ head. See Figure 35.
Figure 34
The FiberCUT™ controller can be directly connected to a PC or multiple FiberCUT™ controllers can be connected to a PC using an Ethernet Switch. o
FiberCUT™ controllers are set at the factory to a static IP address of 169.254.99.12. Typically it is necessary to set the IP address of your PC to the same range as the IP address of your FiberCUT™ controller. o
Connecting the FiberCUT™ controller to a wider network, which may include an internet connection, is also possible. This type of connection adds a level of complexity due to the high level of network traffic.
For example; to connect to the FiberCUT™ controller at the default address, set your PC to an address of 169.254.99.1 with a subnet mask of 255.255.255.0. Refer to your Windows documentation on how to set your IP address.
Figure 35
To connect to the FiberCUT™ controller, select the IP address from the pull down menu and press the connect button. Once a connection is established, the display will change to an image representing the FiberCUT™ being used.
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To run the FiberCUT™ Update (SW0012) software (see Figure 35):
5.5 Manage Connections To add, modify and rearrange IP addresses in FiberCUT™ Monitor, select the Manage Connections… option under the Connections Menu. The Manage Connections screen appears. See Figure 36.
1. Launch the SW0012Rxx.exe application. xx is the current revision number. 2. Enter the controller's IP address and click Connect. If the IP address is unknown, click Find to display all the controllers on the network. An additional software installation may be necessary to use the Find feature. If that is the case, follow the on screen instructions. 3. The updater will display the current Model, Tip Assembly, and Tip configuration assigned to the controller. Make any necessary changes then click Update. 4. A message may appear that the version is already installed.
Figure 36
If changes have been made to the head configuration, click Yes to continue.
5.5.1 Add an Address 1. Click the + button to create a new entry with the default IP address.
Otherwise, click No.
2. Modify the IP address to match the address of the FiberCUT™.
5. A prompt will appear asking whether to save existing Preferences or use default values.
3. Assign a name to the FiberCUT™ and add an optional description.
Click on the appropriate selection to begin updating
4. Click Add & Test to verify the connection and save the address.
OR Click Cancel to stop the update process.
6. Once the update is complete, the head will reset.
To add an address for a FiberCUT™ that is currently offline, click Add Without Testing instead.
You are ready to exit this program and launch FiberCUT™ Monitor.
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To rearrange the order of the addresses, click on a row and drag it to the desired position in the list.
5.5.2 Modify an Address To change the address only within FiberCUT™ Monitor:
You may also sort the addresses by number, name, or description by clicking on the appropriate header.
1. Click on the row of the address you would like to change.
5.6 Temperature Displays
2. Modify the IP address as desired.
The Temperature Displays indicate three different temperature readings in the FiberCUT™ head. See Figure 37.
3. Click Modify & Test to verify the connection and save the address.
If the FiberCUT™ is currently offline, click Modify Without Testing instead.
5.5.3 Reassign an Address To change the address both on the FiberCUT™ and within FiberCUT™ Monitor: 1. If the address of the FiberCUT™ you would like to reassign is not currently listed within FiberCUT™ Monitor, add it by following the procedure in Step 5.5.1.
Figure 37 These temperature readings are valuable information that can indicate problems with contaminated or damaged optics, or poorly aligned fibers.
2. Click on the row of the address you would like to reassign. 3. Modify the IP address as desired.
The temperature of the electronics is usually 5 to 10 degrees warmer than ambient temperature.
4. Click on Reassign and confirm the change.
The FiberCUT™ controller will generate a temperature fault when any of these readings exceed the max temperature limit (45°C – 55°C).
If the change is successful, the new address will be saved.
A fault will also be generated whenever the readings are below 0°C.
5.5.4 Rearrange Addresses The order of the addresses in the list is the same as the order they appear in the Standard View drop-down list. See Figure 32.
5.7 Position Display The Position Display indicates the physical position of the head within its travel. The retracted position is zero with the negative direction toward the extended limit.
When using Multiple View, the order determines which panel has the address. The first address appears on Panel 1, the second address appears on Panel 2, and so on. See Figure 33. The first address is also used as the default address when using FiberCUT™ Update.
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5.8 Active Standoff Display The Active Standoff Display indicates the measured standoff distance as determined by the capacitive height sensor. Readings above 10mm are indicated as >10.0mm.
Figure 38
When the head is not actively tracking a surface (no standoff is selected) the message Height Sensing Disabled is displayed.
5.12 Preferences The Preferences button (see Figure 32 and Figure 33) allows technicians to adjust certain parameters on the FiberCUT™ controller. See Figure 39.
Otherwise, the selected standoff height is displayed.
5.9 Inputs The eight inputs displayed indicate the real time status of the command signals from the robot to the FiberCUT™ controller. See Section 3 of this document manual for a detailed description of these signals.
5.10 Outputs The eight output signals indicate the real time status of the signals that are available to the robot. See Section 3 of this document for a detailed description of these signals. IN POSITION – The head is positioned at the proper standoff from the part. RETRACTED – The head is in the fully retracted position. TIP TOUCH – The tip is making contact with the part. CRASH – A fault has occurred with the head. STAT (1-4) – Four bits that together signify the current fault code.
Figure 39
5.11 Status Display / Fault Code History
This menu is password protected to prevent access by people who should not modify the settings. To access the Settings window, enter the password: cutsetup.
This indicates the current alarm status of the FiberCUT™. Any alarms that may occur while FiberCUT™ Monitor is connected will be recorded in the Fault Code History. The history can be cleared by clicking the Clear button.
With the exception of Simulated Inputs, all changes made are stored directly on the controller and not within FiberCUT™ Monitor. This means each head maintains its own settings, and changes made to the settings of one head will not affect the operation of any of your other heads.
The Clear button is located near the lower right corner of either the Standard View Panel or the Multiple View Panel. See Figure 32, Figure 33, and Figure 38.
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Maximum Temperature – Sets the upper limit for Electronics, Mirror/Collimator, and Nozzle temperature. The thermometers within FiberCUT™ Monitor scale accordingly and exceeding this temperature generates a fault.
5.13 Diagnostic View The Diagnostic view is provided to aid in troubleshooting faults. This mode records all input and output data for two seconds before and after a fault occurs. See Figure 40.
Extended Crash – When enabled, the CRASH output actuates when the head is fully extended.
Inverted Crash – When enabled, the CRASH output is open when there is a crash and closed when there is no crash.
Data is only captured when the computer is connected and the diagnostic software is active.
Enable PLTRA0417 – Enabled when tip retainer assembly PLTRA0417 is used. Prog. Retract Positions – Allows the retract position to be set through a combination of the Height Select Bits and Center Of Travel Bit (see Section 3.3.1 Height Select Bits (HS1-HS3) for more information). Show Simulated Inputs – When checked, a second set of inputs is displayed within FiberCUT™ Monitor. These inputs are designated by orange circles and may be set and cleared by clicking on them. The input seen by the FiberCUT™ is the OR value of the Actual Input and Simulated Input. The Stand Off and Servo and Terminal tabs contain advanced settings that should only be adjusted under the direction of a Laser Mechanisms technician.
Figure 40 Diagnostic View Panel
Sleep Mode – If the head is inactive for the indicated length of time (use the up/down arrows to set the length of time, see Figure 39), the servo motor will turn off and the head will fully extend.
To begin watching for a fault: 1. Click Start and once the Status reads Ready, data collection will trigger on the next change of state of the CRASH bit.
Analog Output – HSU Voltage is the typical output. Other options include Linear Pot Voltage, Electronics Temperature, Collimator/Mirror Block Temperature, or Nozzle Temperature. See the drop down menu shown in Figure 39.
2. Full data can then be saved to a .csv file by clicking Save.
Fieldbus Settings (If Equipped) – Depending on the controller model, an additional button may appear to allow configuration of the Remote I/O Node or IP Address. See Section 3.9 for more details.
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The Status will change to Triggered once a fault is detected, and data will appear on the graph showing the output voltage of the height sensor and linear potentiometer after approximately two seconds.
If necessary, data collection can also be triggered manually by clicking Trigger.
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6 Service Regular maintenance is required for the FiberCUT™ Head. The operating environment has a critical impact on the frequency of maintenance procedures. Consult your Laser Mechanisms representative for guidance.
6.1 Replacing Gas Jet Nozzle Tip 6.1.1 Step 1 a. Unscrew the tip from the tip retainer by turning it counterclockwise. 6.1.2 Step 2 (See Figure 42) a. For PLTRA0360 and PLTRA0369: Check the condition of the O-ring and replace it if necessary. Stretch the Oring over the tip retainer boss.
Figure 42 6.1.3 Step 3 (See Figure 41) a. Thread in a new tip finger tight until it seats solidly (do not use pliers).
OR
6.1.4 Step 4 a. Update the tip selection and recalibrate according to Section 5.4.
b. For PLTRA0417: Check the condition of the isolator and replace if necessary. Available Tip Retainers and Tips
Figure 41 See Appendix E Recommended User-Serviceable Parts List for nozzle part numbers.
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6.2 Tip Assembly Removal and Reinstallation
6.2.2 Step 2 To reinstall the tip assembly on the head:
The tip assembly must be removed to service the focusing optics. See Figure 43.
a. Push the SMB connector over the male SMB connection on the tip assembly by firmly grasping the connector between thumb and forefinger and pushing it straight on.
To remove the tip assembly: 6.2.1 Step 1 a. To remove the tip assembly from the head, unscrew the shroud from the tip assembly to expose the mounting screws.
Verify that the (2) O-rings are properly located inside the housing.
It may feel stiff because of the seal. If the SMB cable has accidentally retracted into the head, compress the Zslide until the cable reappears.
b. Unbolt the tip assembly using a 3mm hex wrench. The screws are captive. c.
Unplug the SMB connector by firmly grasping it between thumb and forefinger and pulling straight off of the tip assembly.
Warning: If the SMB connector is not attached, the system will not work. b. Reattach the tip assembly using a 3mm hex wrench. c.
Thread on the protective shroud.
d. Center the laser beam in the tip according to Section 4.4.
Figure 43
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6.3 Cleaning Optics 3. Soak a clean lens tissue (PLOCK0014 – ® Texwipe Absorband Wipes – or equivalent) with acetone or reagent grade isopropyl alcohol. 4. With the soaked lens tissue wipe the optic in one direction. 5. Repeat steps 3 and 4 three times using a clean lens tissue. 6. Inspect the optic. If there is any dust on it or it appears cloudy repeat steps 2 through 5. If it is clean, proceed to step 7. 7. While holding the optic by its edges place a clean piece of lens tissue over the optic, and then apply a few drops of Tech Spec lens cleaner or reagent grade isopropyl alcohol to the lens tissue. 8. Drag the lens tissue off the surface of the optic in one direction. 9. Repeat step 7 and 8 three times. 10. Rotate the optic 90° and repeat steps 7 and 8 three times. 11. Inspect the optic to make sure that it is clean. 12. Turn the optic over onto a clean lens tissue and repeat steps 2 through 11 to clean the other side.
Optics are very sensitive to dust and debris. It is extremely important to take every possible precaution to ensure the optics remain pristine.
Clean optics in a dust free air-conditioned room.
Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.
ALWAYS handle optics by their edges, never touch the optical surfaces.
ALWAYS wear powder free gloves or finger cots when handling optics and optics holders.
Inspect the optics with high power illumination, such as Laser Mechanisms pen light (part number PLTLS0021) under 2X magnification. The following instructions are provided as a guide only. Laser Mechanisms Inc. cannot be held responsible for any damage to optics resulting from improper cleaning or handling. Cleaning instructions supplied by the optics manufacturer should always be followed.
1. Wash hands with soap to remove all oils, and then put on powder free gloves or finger cots. 2. Hold the optic by its edges and blow any dust off with low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.
DO NOT USE AN AIR COMPRESSOR.
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6.4.2 Step 2 (See Figure 45) a. Remove the cover glass from the holder by applying pressure with your fingers to the surface of the cover glass, opposite the seal.
6.4 Changing the Cover Glass Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.
The seal and cover glass will pop out.
Save the seal.
The cover glass can be changed while the head is mounted to the robot.
Always wear powder free gloves or finger cots when handling optics and optics holders.
6.4.1 Step 1 (See Figure 44) a. Unscrew the shroud from the tip assembly to expose the cover glass holder. It may feel stiff because of the seal. b. Pull the cover glass holder out of the tip retainer assembly.
Figure 45 6.4.3 Step 3 a. Install the new cover glass by placing it into the holder. See Figure 45.
It may be necessary to use the 3mm hex wrench to help pull out the cover glass holder.
6.4.4 Step 4 a. Press the Teflon seal into the holder to retain the cover glass. Replace the existing seal with a new one if it appears damaged. b. Reinsert the cover slide holder into the tip assembly. Verify that the orientation of the cover slide holder is correct. See Figure 44.
Figure 44
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6.5 Changing the Focusing Lens Optics To change the focusing lens, the tip assembly must be removed and relocated to a clean dry area. Individual optics may be cleaned (according to Section 6.3) or replaced. 6.5.1 Step 1 a. Remove the tip assembly as outlined in Step 6.2.1. 6.5.2 Step 2 a. Measure and record the position of the lens holder as shown in Section 4.5.
Figure 46 6.5.4 Step 4 Blow the dust off of the optics using canned gas or clean nitrogen.
See Figure 46 for steps 3-6.
a. Insert a new lens and spacer into the lens cartridge as shown in Figure 47. It is critical the lens and spacers are inserted as shown.
6.5.3 Step 3 a. Using PLLIT0028, unthread the lens retainer nut as shown in Figure 47.
b. Hand-tighten the retainer nut using PLLIT0028. Over-tightening the nut will cause the lens to distort.
Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.
Always wear powder free gloves or finger cots when handling optics and optic holders.
Inspect the optics with high power illumination, such as Laser Mechanisms pen light (part number PLTLS0021) under 5X magnification.
b. Carefully remove the lenses and note the orientation of the lenses, spacers, and seal rings.
Figure 47 6.5.5 Step 5 a. Measure the position of lens holder to confirm it has not moved. b. Reinstall the tip assembly as outlined in Step 6.2.2. 6.5.6 Step 6 a. Perform the tip alignment procedure according to Section 4.4.
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6.6.2 Step 2 a. Unbolt head using 5mm hex wrench as shown in Figure 48.
6.6 Removing the Cutting Head from the End of the Robot To perform most service procedures, it is necessary to remove the cutting head form the end of the robot. Remove the head when cleanliness is important, especially if the procedure involves optic maintenance.
Take the cutting head to a clean area to insure unwanted dust and debris do not contaminate optics and other critical parts of the head.
Wipe the head clean of any foreign matter prior to removal from the robot.
Take care to note orientation of cutting head.
b. Separate the head from the mount until the alignment pins are disengaged.
6.6.1 Step 1 a. Remove the fiber optic cable from the cutting head. Special attention must be given to the fiber optic cable. Care must be taken to insure dirt and debris do not contaminate the glass block at the end of the fiber.
Damage will occur if: Figure 48
The output is not covered with manufacturer’s cap.
The fiber input is not protected by the provided dust cover.
b. Turn off the water supply and disconnect the water fittings. c.
Remove the purge air and assist gas lines.
d. Disconnect the control wire. e. Leave the robot mount plate and crash protection in place.
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6.7 Fiber Collimator Assembly Removal and Reinstallation
b. To remove the fiber collimator assembly from the cutting head, use steady pressure to unseat it from the o-ring seal.
The collimator assembly must be removed to replace the turning mirror and collimator optics. To remove the Collimator assembly:
The plate is dowel-pinned in place, so pull it straight out.
6.7.1 Step 1 a.
Remove cutting head from robot. See Section 6.6.
Verify that the o-rings come out with the assembly and do not remain in the head.
In order to keep out debris, it is recommended to move the head to a horizontal orientation.
To reinstall the collimator: 6.7.3 Step 3 a. Reinstall the fiber collimator assembly from the cutting head by reversing the steps followed in 6.7.1 – 6.7.2.
6.7.2 Step 2 a. Unbolt the fiber collimator assembly from mount by loosening the (4) screws with a 3mm wrench. See Figure 49.
Take special note not to snag, pinch or tangle any wires inside the head during reinstallation.
Figure 49
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6.8 Turning Mirror Removal and Reinstallation The turning mirror is located in the fiber collimator assembly. See Figure 50.
Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.
Always wear powder free gloves or finger cots when handling optics and optic holders.
Figure 50 6.8.3 Step 3
6.8.1 Step 1
a. Remove the mirror from the cap by putting a bent wire hook into the slot and gently applying pressure from the underside of the mirror. See Figure 51.
a. Remove the fiber collimator assembly from the cutting head. See Section 6.7. 6.8.2 Step 2
a. Remove the mirror cap using a 3mm hex wrench.
The screws are not captivated.
The mirror should remain in the cap as you remove it from the body.
The heat sink spring should remain in the mirror cap. If the heat sink spring sticks to the back of the mirror, remove it from the mirror and return it to the deeper of the two pockets.
b. Separate the cap from the collimator assembly until the alignment pins are disengaged.
Note the correct orientation for disassembly in Figure 50.
Figure 51
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6.8.4 Step 4
6.9 Changing the Collimating Lens Cartridge or Optics
a. Put a small amount of thermo compound (PLTHC0001) on the heat sink spring located in mirror cap.
Select only the approved Laser Mechanisms’ mirror part number PLTRG0041.
DO NOT SUBSTITUTE – The thickness and coating of the mirror are critical.
The recommended procedure is to change the entire collimating lens cartridge; the fiber collimator must be removed from the cutting head. 6.9.1 Step 1 a. Remove fiber collimator assembly from cutting head. See Section 6.7. 6.9.2 Step 2 (See Figure 52)
b. Place the mirror inside of the mirror cap with the coated side up.
a. Loosen the clamp screw with a 3mm hex wrench.
6.8.5 Step 5
b. Unthread the fiber input connector from the fiber input body.
a. Install the cap onto the fiber collimator assembly by carefully sliding it over the dowel pins. b. Replace and tighten the cap screws using a 3mm wrench.
Figure 52
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6.10 Changing the Collimating Lens Optics
6.9.3 Step 3 (See Figure 53) a. Unthread the cartridge retainer nuts using a spanner wrench (PLLIT0028).
Laser Mechanisms recommends purchasing the complete lens cell and returning any defective cell for refurbishment.
b. Slide the lens cartridge out of the fiber input body.
Note the orientation of the lens cartridge for reassembly.
The optics MUST be loaded in the orientation shown in Figure 54 and Figure 55. Failure to follow these guidelines can result in damage to all optical elements, including the fiber. As an alternate procedure, individual optics may be cleaned (according to Section 6.3) or replaced. Follow the instructions in steps 6.9.1, Step 1 through 6.9.3, Step 3, then: Alternate 6.10.4 Step 4
Figure 53
a. Using PLLIT0028, unthread the lens retaining nut as shown in Figure 54.
6.9.4 Step 4 (See Figure 53) a. Slide a new lens cartridge into the fiber input body.
Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.
Verify the orientation of the lens cartridge for reassembly.
b. Rethread the cartridge retainer nuts using a spanner wrench (PLLIT0028). 6.9.5 Step 5
Always wear powder free gloves or finger cots when handling optics and optic holders.
a. Reinstall the fiber collimator assembly by reversing the steps in Section 6.7. 6.9.6 Step 6 b. Perform the tip alignment procedure according to Section 4.4.
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Inspect the optics with high power illumination, such as Laser Mechanisms pen light (part number PLTLS0021) under 5X magnification.
b. Carefully remove the lenses and note the orientation of the lenses, spacers, and seal rings.
Figure 54 Alternate 6.10.5 Step 5
Blow the dust off of the optics using canned gas or clean nitrogen.
a. Insert new lenses and spacers into the lens cartridge as shown in Figure 55.
It is critical that the lenses and spacers are inserted as shown. Figure 55
b. Hand-tighten the retainer nut using PLLIT0028.
Alternate 6.10.6 Step 6 a. Reinstall the fiber collimator assembly by reversing steps followed in Section 6.7.
Over-tightening the nut will cause the lens to distort.
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e. Unplug ONLY the 2 conductor motor wire connected to the height sense card. See Figure 57.
6.11 Motor Removal and Reinstallation The following procedures refer to motor part number PLMOT0022. To remove the motor: 6.11.1 Step 1 (see Figure 56) a. Remove the cutting head. See Section 6.6. b. Move the cutting head to a clean environment to prevent contamination of the optics. c.
Unscrew and remove the nut holding the height sense card (HSU) onto the motor cover box.
d. Loosen the (4) captive M4 bolts and remove the motor cover box. Set the motor cover box aside. Figure 57 6.11.2 Step 2 (see Figure 58) a. Inside the motor compartment, remove the (4) M3 socket head cap screws that hold the motor onto the housing. b. Lift up on the moving head slide to lift the actuator follower block off of the motor cam arm. c.
Remove the motor assembly from the housing.
Figure 56
Figure 58
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6.11.3 Step 3 (see Figure 59) a. Loosen, but DO NOT REMOVE, the clamp bolt from the clamp arm.
If a screw falls into the body of the FiberCUT™ head, retrieve it by removing the lower part of the housing body. Remove it by unthreading it or turning it counterclockwise).
b. Loosen, but DO NOT REMOVE, the cam arm set screw. c.
Pull the cam arm off of the motor shaft.
d. Remove the (3) M2.5 bolts that hold the motor onto the assembly plate. e. Remove the motor from the assembly plate.
Figure 60 For steps d-f, see Figure 61. d. Push the motor cam arm onto the motor shaft. Figure 59 To reinstall the motor: 6.11.4 Step 4 For steps a-c, see Figure 60.
The cam arm should be flush with the end of the motor shaft.
Take care that the flat on the motor shaft is in line with the set screw.
It may be necessary to slightly loosen (turn counterclockwise) the cam arm set screw. Use a 2 mm hex wrench.
a. Insert the new motor into the assembly plate.
Orient the wires out of the motor in the 5 o’clock position as shown.
e. Tighten (turn clockwise) the cam arm set screw. Use a 2 mm hex wrench.
b. Turn the FiberCUT™ head and verify that the threaded holes on the shaft side of the motor are aligned with the holes in the housing. Rotate the motor to align the holes as necessary. c.
The cam arm set screw should contact the flat of the new motor shaft.
Reinstall the (3) M2.5 socket head cap screws previously removed in step 6.11.3 Step 3.
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f.
Then, reinstall the clamp bolt. Use a 2.5 mm hex wrench.
Figure 62
Figure 61 g. Push the moving head up and reinstall the motor assembly into the housing using the (4) M3 socket head cap screws removed in step 6.11.2, Step 2. See Figure 62.
Insert the cam arm under the follower dowel
The cam arm must be oriented as shown in Figure 62.
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6.11.5 Step 5 a. Connect the 2 conductor motor wire to the height sense (HSU) card. See Figure 57.
6.12 Dust Seal Removal and Reinstallation To remove the manifold seal: 6.12.1 Step 1 (see Figure 64) a. Remove the 4 M4 screws and the dust cover.
For steps b and c, see Figure 63. b. Attach the motor housing box using the (4) captive M4 bolts. c.
b. Use an appropriate tool to peel the manifold seal off of the shroud.
Reattach the fiber and communication cables. See Section 6.6.
d. Turn the power back on to the FiberCUT™ head. See Section 6.6.
Figure 63
Figure 64
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To reinstall the dust seal: 6.12.2 Step 2 (see Figure 65)
Figure 65 a. Verify that the bottom of the cover, especially the lip area, is clean. b. Press the manifold seal (part number PLMSR0031) against the cover along the lip until the entire seal is pressed against the inside of the cover.
No adhesive is used to install the seal.
There is a “smooth” side and a “fuzzy” side to the seal. The “smooth” side is pressed against the lip area of the shroud. The “fuzzy” side creates a dust barrier between the main body and the shroud.
The ends of the seal, cut at a 45° angle, must meet together without any gaps.
An appropriate sharp tool may be helpful.
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7 Specifications CUTTING HEAD Power Rating .............................................................................................................................. up to 4 kW Focusing Lens (Effective Focal Length) ................................................ 75mm, 104 mm, 130 mm, 150 mm Focusing Lens (Diameter) ................................................................................................................. 28 mm Clear Aperture ................................................................................................................................... 25 mm Nozzle Tip .......................................................................................................................... Various Shapes Assist Gas Pressure ............................................................................................................... up to 20 BAR Gas .................................................................................................................................... Female 1/8 NPT Water Ports ........................................................................................................... 6 mm tube to M5 fittings Weight ................................................................................................................................................ 3.2 kg Height (Center Of Travel) ........................................................................................................ 304, 333 mm Slide Travel .................................................................................................................................... ±8.5 mm Max. Travel Speed .................................................................................................................. 175 mm/sec. Standoff Distance Range (1 mm Recommended) .......................................................... 0.5 mm to 2.0 mm
COLLIMATOR Effective Focal Length (Doublet, Fused Silica) .................................................................. 78 mm, 102 mm Recollimating Lens (Diameter) .......................................................................................................... 28 mm Clear Aperture ................................................................................................................................... 25 mm Fiber Socket (Others Available On Request) .................................... QBH, HCL-8, LLK-B, QD, LCA, PIPA
CONTROL BOX Sealed Enclosure ............................................................................... 380 mm L x 300 mm W x 160 mm H Single Interconnect Cable ................................................................................................... up to 15 m long Number of Standoff Settings ...................................................................................................................... 7 Electrical Supply ........................................................................................ 85-264 VAC, 1-Phase,47-63 Hz Interface Inputs ................................................................ 5-24 VDC, 2.2 kΩ impedance, optically isolated Interface Outputs ................................................ 12-24 VDC, 150 mA max., sink/source, optically isolated Specifications are subject to change without notice.
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8 Troubleshooting Most of the faults can be cleared by moving the head away from any objects, turning off all of the I/O’s, followed by resetting the head by activating the RST input for ~0.1sec. In some cases just activating RST for ~0.1sec will also clear the fault.
SYMPTOM
CAUSE The head has reached the extended or retracted limit while sensing.
REMEDY Turn off HS1, HS2, HS3, AIE and HOLD inputs to place the head in retracted position mode.
Head has had a fault or crash.
Reset head.
Power is not turned on to the controller.
Check power and all connections to the controller and head.
Fault: 1: Head Not Extended
Something is preventing the head from fully extending.
When the controller is first powered up, the head must be able to fully extend. Jog the head away from the object and then turn power on to the controller.
Fault: 2: Hit Retract Limit
The head has collided with an object causing the head to reach the retract limit.
Jog the head away from the object and reset.
Fault: 3: Calibration Fault
The controller has not received the proper response from the height sensor.
The tip may be shorted or the sense cable may be broken. Replace the nozzle or sense cable.
Crash interlock is not satisfied (INT1 and INT2)
Fault: 4: Extending Watchdog
The motor is being told to extend continuously.
An object is touching the head preventing it from extending. Move the head away from the object. The drive system has failed. Replace the motor or drive mechanisms. An object is touching the head preventing it from retracting. Move the head away from the object.
Fault: 5: Retract Watchdog
The motor is being told to retract continuously.
Fault: 6: Temperature Watchdog
The controller is not getting the proper response from the head electronics.
Replace the head-control cable or head electronics module.
One or more optics have failed.
Inspect all optics and fiber, replace as needed.
The tip is not centered.
Check tip centering. The tip may need to be replaced.
Insufficient water-cooling.
Make sure proper water temperature and flow are maintained to the head.
Fault: 7: Overtemp, Mirror 8: Overtemp, Focus Lens & Nozzle Assembly 9: Overtemp, Head Electronics
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The drive system has failed. Replace the motor or drive mechanisms.
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SYMPTOM
CAUSE
REMEDY Check the temperature sensors in the head for broken wires or shorts.
Fault: 10: Temperature Error
Sensor failure in head.
Fault: 11: Not Centered
Collision with the head while COT is active.
An object is touching the head preventing it from reaching position. Move the head away from the object.
Fault: 12: Hit Limit While Retracted
Collision with the head while in retracted position.
Jog the head away from the object and reset.
Head is failing to sense properly on the part.
Fault: 13: Height Sensor (HS) Position Error Or head is chattering on the part.
An object is touching the head preventing it from reaching position. Move the head away from the object. The internal sensor cable is not connected. Remove the tip assembly and reattach the internal SMB connector.
The height sensor failed to calibrate properly on the previous retract.
Prior to sensing on the part, place the head in COT followed by a Retract. This recalibrates the height sensor. Do not touch the tip while the head is retracting.
The head is trying to sense the edge or corner of the part.
In order to sense accurately, the tip must see a relatively flat surface. Edges may not provide adequate surface area. Selecting a higher standoff may resolve this issue.
Improper tip is selected.
Make sure the Tip Select input matches the corresponding tip being used.
Fault: 14: Hold Position Error
Collision with the head while HOLD is active.
An object is touching the head preventing it from reaching position. Move the head away from the object.
Fault: 15: Failed To Retract
An object is preventing the head from fully retracting.
Inspect the head for objects that may be interfering with the motion. The obstruction may be internal.
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9 Appendix A – Coolant Specifications The cooling manifolds are designed to be operated on either a closed-loop cooling system or facility tap water. For either type of system the requirements in the table below must be met.
Inlet Pressure Inlet Temperature Hardness (Equivalent to CaCO3) pH
1.6 liter/minute @ 2 BAR minimum 170 to 520 kPa ≥room temperature / >dew point <250mg/liter 6 to 8
Particulate Size
<200 microns in diameter
Minimum Flow Rate
10 Appendix B – Assist Gas Specifications Impurities in the assist gas such as hydrocarbons (THC) and moisture (H 2O) can damage optics, cause power fluctuations and result in inconsistent cuts. See the table below for recommended assist gas specifications. GAS
PURITY
MAX H2O ppm
MAX THC ppm
Oxygen Nitrogen
99.8% 99.998%
<5 ppm <5 ppm
<1 ppm <1 ppm
Argon Helium
99.998% 99.998%
<5 ppm <5 ppm
<1 ppm <1 ppm
Impurities can also be picked up in the supply lines. Non-metallic materials can allow oxygen and moisture to permeate the system and can be a source of dust and hydrocarbons. Stainless steel lines and fittings are recommended. Use filters that remove particles down to .01 microns and purifiers that guard against oil or water from getting into the optical system. Regulators with a stainless steel diaphragm are recommended. Industrial regulators can aspirate air and the neoprene diaphragm can be a source of hydrocarbons.
11 Appendix C – Beam Delivery Purging The beam delivery system must be purged with clean, dry air {specification to meet or exceed ISO 8573.1:2001 Class 1.5.2}; Solids <100 particles per cubic meter of 0.1-0.5 µm size, and <1 particle per cubic meter of 0.5-0.1 µm; Water dewpoint <+7º C; Oil <0.1 mg per cubic meter. Purge flow rate is 1400 liters/hr (50 SCFH) @ 20 kPa. A self-regenerating desiccant air dryer filter unit (PLKIT0188) is available as an option from Laser Mechanisms.
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12 Appendix D – Fiber End Types Fiber End Type
Sample Image
HLC or QBH
QD or LLK-D
LCA
Q5 or LLK-B
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13 Appendix E – Recommended User-Serviceable Parts List For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further assistance. ITEM PART # DESCRIPTION FIBER INTERFACE ASSEMBLY 1 Fiber Interface Assembly (Contact Laser Mechanisms) 2 PLFTG0081 Tube Fitting 3 PLTRG0041 Total Reflective Mirror 4 PLHSK0003 Heat Sink Spring COLLIMATOR FIXED LENS HOLDER 75mm BFL 5 PLFLH0243 Collimator Fixed Lens Holder 75mm BFL (Complete Assembly) 6 PLYFS0013 Collimating Lens For PLFLH0243 7 PLLSR0002 Lens Seal Ring 8 PLLBR0002 Lens Backup Ring 9 PLLBR0005 Lens Backup Ring 10 PLLRN0026 Lens Retainer Nut COLLIMATOR FIXED LENS HOLDER 100mm BFL 11 PLFLH0229 Collimator Fixed Lens Holder 100mm BFL (Complete Assembly) 12 PLYFS0007 Collimating Lens For PLFLH0229 7 PLLSR0002 Lens Seal Ring 8 PLLBR0002 Lens Backup Ring 10 PLLRN0026 Lens Retainer Nut CABLES 13 PLCAB0489 Controller Interface Cable 14 PLCAB0487 Sensor Cable ADJUSTABLE LENS HOLDER 100mm BFL 15 PLALH0137 Adjustable Lens Holder 100mm FL (Complete Assembly) 10 PLLRN0026 Lens Retainer Nut 8 PLLBR0002 Lens Backup Ring 7 PLLSR0002 Lens Seal Ring 16 PLYFS0012 Lens 100mm BFL ADJUSTABLE LENS HOLDER 125mm BFL 17 PLALH0138 Adjustable Lens Holder 125mm FL (Complete Assembly) 10 PLLRN0026 Lens Retainer Nut 8 PLLBR0002 Lens Backup Ring 7 PLLSR0002 Lens Seal Ring 18 PLYFS0016 Lens 125mm BFL COVER GLASS HOLDER 19 PLFLH0123 Fixed Lens Holder 20 PLLCG0034 Lens Cover Glass 21 PLMSR0017 Manifold Seal Ring TIP RETAINER ASSEMBLIES 22 PLTRA0360 Tip Retainer Assembly 100mm FL 23 PLTRA0369 Tip Retainer Assembly 125mm FL 24 PLTRA0417 Tip Retainer Assembly 125mm FL – Narrow Profile
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ITEM SCREWS 25 O-RINGS 26 ISOLATORS 27 NOZZLES 28 29 30 31 32 33 34 35 36 37 38 SEALS 39 TOOLS
PART #
DESCRIPTION
PLSCR0034
Custom Socket Head Cap Screw
PLORG0017
O-ring
PLISR0033
Tip Isolator
PLGJT0623 PLGJT0522 PLGJT0608 PLGJT0563 PLGJT0682 PLGJT0711 PLGJT0226 PLGJT0227 PLGJT0172 PLGJT0173 PLGJT0523
Slim Style Tip 1.5mm Orifice Blunt Style Tip 1.2mm Orifice Blunt Style Tip 1.5mm Orifice Narrow Style Tip 1.2mm Orifice Narrow Style Tip 1.5mm Orifice Tight Access Style Tip 1.5mm Orifice TRA0417 Style Tip 1.0 mm Orifice TRA0417 Style Tip 1.2mm Orifice TRA0417 Style Tip 1.5mm Orifice TRA0417 Style Tip 2.0mm Orifice TRA0417 Style Tip 2.5mm Orifice
PLMSR0031
Manifold Seal Ring
PLLIT0028 PLTHC0001
Lens Insertion Tool Thermo Compound
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Figure 66
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14 Glossary Assist Gas Any gas that is applied to the working point on the material to assist the laser process (also referred to as cover gas or shield gas). CFN Cold Formed Nozzle Cover Gas (See Assist Gas) FL Focal Length HSU Height Sensing Unit I/O Inputs(s) and Output(s) PSI Pounds per Square Inch SHCS Socket Head Cap Screw SMA Sub-Miniature-A 50 ohm connector with a threaded coupling interface. Shield Gas (See Assist Gas) TRA Tip Retainer Assembly
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Laser Mechanisms, Inc. 25325 Regency Drive • Novi, Michigan 48375 USA Phone: (248) 474-9480 • Fax: (248) 474-9277 In Europe: Phone: +32(0)92 18 70 70 • Fax: +32(0)92 18 70 79 Web: www.lasermech.com • E-Mail:
[email protected]
