Training Laser Process
04.08.2015
Laser source
Trumpf TruDisk4006
Beamquality: 24 mm*mrad
4kW on product part
4-way Beamswitch
Software TruControl
Fiber LLK-D 06 50m
Light Amplification by Stimulated Emission of Radiation
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 2
www.kuka-systems.com
Laser fiber
1
1
2
3
4
1 Cable sheath with steel cladding
2 Safety circuit
3 Protective shell
4 Optical fiber
Structure and workings of a fiber
The bending radius of the laser light
cable should not be less than 200 mm!
1 Core
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 3
www.kuka-systems.com
2 Cladding
3 Refraction index profile
Panel computer with TruControl laser maintenance
The symbols in the column "Maintenance status" (2) show
the state of a component:
1
If a component must be serviced, a message is displayed.
2
The context bar (2) contains buttons with the following
functions:
3
1 Maintenance works
2 Context bar
3 Maintenance status
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 4
www.kuka-systems.com
Laser diagnosis
The message types are marked with the following symbols:
1
2
3
The context bar (3) contains various buttons with the
following functions:
1 Filter settings
2 Message list
3 Context bar
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 5
www.kuka-systems.com
Laser multi PLC interface (MPI), overview
Selecting dialogs Multi PLC interface (MPI), overview and Slot number
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 6
www.kuka-systems.com
Laser “light paths status"
The "Light paths status" display shows by
means of symbols the status of a light path:
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 7
www.kuka-systems.com
Laser safety class 4
If laser safety class 4 is present, the work station must be labeled as follows:
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 8
www.kuka-systems.com
Laser safety
The following dangers must be anticipated during operation:
•
Danger of invisible laser radiation.
•
Danger of thermal damage to living tissues (skin).
•
Danger of photochemical damage (eye).
•
Danger of air contamination caused by emissions from the workpiece.
•
Danger of heat from the high energy input.
•
Danger of fire from intense heating.
The safety instructions of the laser manufacturer and the manufacturer
of the laser optics must also be observed.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 9
www.kuka-systems.com
Robot software LaserTech
Item
Description
1
Laser power at 100% velocity
2
Laser power at virtually 0% velocity
3
Laser program number
4
Ramp time
Time that elapses after activation before the
laser reaches full power
LaserTech status keys on the Robot Panel
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 10
www.kuka-systems.com
ALO3
Technical functions of ALO3
Technical functions of ALO3
Seam tracking in lateral-direction
Seam tracking in z-direction
The telescope arm tracking the seam Telescope arm and autofocus function
and moves the optical lens with the tracking the seam and move laserspot
laser beam in lateral-direction.
in tool centre point, when the height
changes.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 12
www.kuka-systems.com
Laser Brazing
Principle of defocusing
Fiber
Collimation
Upward shift
Downward
shift
zF > 0
zF < 0
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 13
www.kuka-systems.com
The focus diameter is
Subject to the wire
size and the type of
welds.
Seam tracking forces for different types of weld joints
A) Generally, no lateral seam-tracking force is necessary when the seam joint guides equally on
both sides (for example, flanged butt weld).
B) On the whole, no additional lateral force is required for a fillet seam in a lap joint when the ALO3 is at an
inclined angle of incidence during processing. In this case, the seam-tracking force is either very low or neutral.
C) A lateral seam-tracking force can be applied for single-sided weld joints (for example, fillet weld) to guarantee
the wire bears correctly against the leading edge. Viewed from front (from X direction): +NFK to left in Y direction,
-NFK to right in Y direction.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 14
www.kuka-systems.com
Settings Lateral beam alignment on the optics module (adjustable)
The adjustable optics module can be adjusted by a one-dimensional re-positioning (± 0.8
mm) so that the lateral position of the focal point is aligned with the process.
Remove the cover plate
Before adjusting, you must remove the cover plate
(1). The cover plate protects the settings dial from
contamination and water. To do so, loosen the four
M3x10 cylinder head screw with anti-vibration
washers.
Adjust the focus
The settings dial (2) is located under the cover plate.
The dial turns in intervals of 0.025-mm steps (four
steps are equal to 0.1 mm). The focus can be moved
along the Y axis within a range of ± 0.8 mm. The
blade (3) can be used as a reference point.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 15
www.kuka-systems.com
Varying the exposed length of wire
Subject to process parameters and the diameter of the
filler wire, it is possible to vary the length of the
exposed wire (9) within a range of about 7 – 10 mm by
loosening both M4x10 socket-head cap screws (5).
Select the wire feed nozzle (8) that is screwed to the
wire-guide module outlet, according to the diameter
of the filler wire. The wire feed nozzle is a wearing
part that must be regularly.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 16
www.kuka-systems.com
Definition of the coordinate system
Direction along the X axis: Direction of feed process
Direction along the Y axis: Lateral direction of deflection
of the swivel axis
Direction along the Z axis: Direction of movement for the
telescoping arm and the tracking position of the focal point
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 17
www.kuka-systems.com
Electrical connections and power supply Scansonic
Start
Connecting the scapacs® plug to the controller
Remove the cover (1) from the corresponding plug port on the controller
(please refer to connector positions). Unscrew the two or four M3x10
cylinder head screws. An O-ring is used to hold the screws in place.
Connect the plug. Ensure that the O-ring is seated correctly on the
underside of the connector. The pins on the scapacs® plug (1) are coded
so that it can only be properly inserted. Finally, tighten the two or four
M3x10 cylinder head screws.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 18
www.kuka-systems.com
Optical data sheet Scansonic
Validation
The data is valid for all scapacs devices with the
same system number, which is specified in the
associated configuration data sheet.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 19
www.kuka-systems.com
Overview of the optical layout
The optical layout is showing
the arrangement of the most
important optical components
Theoretical Data Scansonic
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 20
www.kuka-systems.com
Theoretical Data Scansonic
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 21
www.kuka-systems.com
Password HMI Scansonic
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 22
www.kuka-systems.com
Normal:
user
Maint.:
23INSTALL
Service:
2SERVICE
Operating panel, seam-tracking force
Force no. X
The required force that ensures proper
press against weld butt joint
(SAFORCE).
Force balancing
Force controller offset – to compensate
for environmental influences (gravity).
This is contingent on the fixed position
or on additional mounted loads that
could influence the force sensor.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 23
www.kuka-systems.com
Operating panel SA range
Range type / CTRL no. X
Operating ranges can be defined so
that the system controls will display
when the swivel axis is within the
specified range. This allows you to
check whether the swivel axis is
located in the vicinity of your workpiece seam.
Type 0 – Absolute, with no stop
Type 1 – Relative, with no stop
Type 2 – Absolute, with stop
Mid-point no. X
Starting point for defining the operating
range.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 24
www.kuka-systems.com
Operating panel, LA position
Description
The parameters associated with the
switching commands (LA_Pos and
LA_Auto) can be entered or shown in
the corresponding fields in the
operating panel. The values can vary
within specific ranges depending on
the configuration of your processing
head.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 25
www.kuka-systems.com
Services, Saving changes permanently
Description
The "Services" menu option can be
used for acknowledging errors and
warnings, for saving OD entries and for
performing backups.
Access level and function
Normal accesd
No functions.
Maintenance access
Save changes permanently and
acknowledge errors.
Service access
All functions.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 26
www.kuka-systems.com
Maintenance Check list ALO3
Some components in the processing head must be regularly maintained.
Normally, a maintenance interval of eight hours is adequate
Bezel, fibre coupling
– Check the protective-glass bezel (additional protective cover on the fibre-optic plug) for contamination
and welding penetration.
– Conduct a periodic performance test
Protective-glass quickchange drawer
– Check that the protective glass in the quick-change drawers not damaged or dirty (with deposits or
welding splatter). Replace if necessary.
Wire guide module
Wire feed nozzle
Filler wire conduit
Exposed length of wire
– Check for secure attachment
– Check the wire play for snugness
– Check for contamination and dirt
– Check for wear
– Check the exposed length of wire
Cooling water lines and connections
– Check for leakage
– Check that the coolant flows freely
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 27
www.kuka-systems.com
Cross-jet module
Cleaning or replacing the cross-jet bezel
The cross-jet module protects the optical
components of the processing head and extends
the life of the protective glass. The cross-jet bezel
provides extra protection from process splashing.
Inspect the cross-jet bezel (1) periodically to make
sure it is securely attached and to ensure there
are no contaminants that could impair the beam.
Pull the bezel out from the cross-jet in order to
clean it. There will be light resistance from two
spring-loaded plungers as you pull it out.
When reinserting the bezel, make sure that the
notch in the bezel points towards the cross-jet
module. This will ensure that the spring
mechanism snaps in properly.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 28
www.kuka-systems.com
Protective-glass quick-change drawer
Pull out the quick-change drawer
Open the locking lever (1) and pull out the quickchange drawer from the safety glass module (a:
closed / b: open).
Remove the protective glass
The safety glass (3) is quickly secured by means
of a pressure ring (2) in the quick-change drawer.
Remove the pressure ring from the retaining ring
(4) – use a screwdriver if necessary. The retaining
ring then remains in the quickchange drawer.
Check the retaining ring. Put in the protective
glass and secure.
Check the retaining ring (4) for damage. This is
important since the ring also acts as a seal.
Push in the quick-change drawer
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 29
www.kuka-systems.com
Wire feed nozzle
Examine the wire feed nozzle and replace if necessary.
Check the following aspects of the wire feed nozzle every
eight hours and replace if necessary:
– Secure attachment
– Low level of wire play
– Interference due to contamination or dirt
Observe the tolerances of the wire feed nozzle. Following
replacement, check the exposed length and the lateral
position of the wire.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 30
www.kuka-systems.com
Filler wire conduit
Examine the filler wire conduit and replace if
necessary.
Check the filler wire conduit (1) regularly for signs of
wear or damage and replace if necessary.
When installing the replacement conduit, it should be
inserted until it reaches the locator hole in the wire-feed
nozzle (2). It is possible to insert filler wire conduits with
an outer diameter of up to 4.8 mm into the locator hole of
the wire feed nozzle. Then screw the core clamp tight.
Following replacement, inspect the exposed length and
the lateral position of the wire.
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 31
www.kuka-systems.com
Position Laser / Wire
Check Crosshair on Lessmueller
Example
Password: llt
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 32
www.kuka-systems.com
Timing diagram Robot / Lessmueller
Outputs Robot (to Lessmueller)
Part No. OUT_xxx - xxx
End
Part Start OUT_xxx
Seam No. OUT_xxx - xxx
Start
Weld Start OUT_xxx
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 33
www.kuka-systems.com
Software / Communication
Robot
•
•
•
•
End
Training Laser
KUKA Systems GmbH | P-RT | Voetterl | 04.08.2015 | page 34
For an optimal use, configuration and monitoring
of the system the following software is included:
www.kuka-systems.com
Weldeye-server: analysis of the pictures
Weldeye-client: image and configuration
Weldeye-player: playback of recorded weldings
Weldeye-tester: functional test of camera and lighting