2.2 Cutting Head Design

After the optical fiber is connected and fixed to the cutting head, fix the cutting head onto the machine tool with screws (verticality should be ensured). Make sure the connectors on the cutting head are connected properly before subsequent operations.

Figure 2-3 F300 dimension (for reference only)

2.3 Functions

1) Real-time automatic focusing in AUTO mode. Take HAFCH150 for example. The formula is: the current coordinate of "P104W" value is the set focus value. Focus offset value is set in the machine tool parameter "RefPositionDistance" (this cutting head defaults to -7400μm.). PLC and the positive & negative limits of the “W”value in the machine tool parameters are based on this. When M=1.5, the setting range of this value is [-8.mm, -5.mm]; and when M=2.0, the range is [-11.7mm, -8.6mm]. Alarm will occur in PLC if the range is exceeded. In the machine

tool parameters:

2)When piercing stages and the focus position set during cutting are different, piercing or cutting will be carried out after automatic focusing is in place.

3)W-axis has an origin. Positive limit is on the upper side; negative limit on the lower side. When positive & negative limits are sensed, or incorrect operation reaches the two limits, an alarm will occur and W-axis will stop running.

4)The 4-axis button on the operation panel of the machine tool can be used. When the positive & negative limits of the hardware cause an alarm, manually move W-axis in the opposite direction.

5) Be sure to set W-axis back to reference point; failure to do so may cause serious faults.

6)Normally, it is advisable to set the performance parameters of W-axis in this way:

Axis type: straight axis. Max. speed: 3m/min. When the drive is 30W, the acceleration is 2.5m/s2; and when the drive is 100W, the acceleration is 5m/ s2 (KV=3).

2.4 Focus Offset Settings

2.4.1 Zero Focus Settings of 701 System

Cut the figure shown below. Cut 13 equally spaced line segments using a focus of -3 to +3 (step length: 0.5mm):

The steps to execute the automatic focus-finding program are as follows:

(1)Take HAFCH150 for example. Set the parameter "RefPositionDistance" as default focus offset value (-7400μm) to initially set focus offset.

(2) Execute the automatic focus-finding program: The internal contour of the program is 13 straight line segments. The focus position between adjacent line segments changes 0.5mm. The shortest line segment is -3mm, and the longest 3mm (the span can be properly adjusted during accurate calibration.)

(3) Find the value indicated by the finest cutting seam. Set this value to "A", and calibration rate to " \mathsf { B } " . See Table 1 for calibration rate (for reference).

(4) Modify origin offset value:

Calibrate the origin offset value "RefPositionDistance" by the formula below:

The auto-focusing cutting head \ " { \sf H A F C H 1 5 0 . 0 0 - 0 0 A " } can be a case in point:

When "RefPositionDistance" is set to [-7400] (unit: μm) and the 7th line that has been cut is the finest cutting seam, the offset value:

When "RefPositionDistance" is set to [-7400] (unit: μm) and the5th line (-1.0mm marked in the figure above) is the finest cutting seam, then the offset value:

(5)Save the machine tool parameters, and the focus-finding is completed.

Chapter 3 Installation

3.1 Safety Precautions

3.2 Package Inspection

3.3 Installation

3.3.1 Ceramic Ring Replacement

Figure 3-1 Method of replacing ceramic ring (for reference only)

Note:

The original O-ring must be used at the connection between the ceramic ring and the sensor.
Before locking the ceramic ring, be sure to clean the dirt inside the thread.

3.3.2 Fiber Connector Installation Precautions

1) If the on-site installation environment is bad, clean the dust in the air in advance, or choose to install in the early morning when there is less dust.

2) Before using the fiber protective sleeve, be sure to clean the inside of the sleeve, and seal the sleeve mouth with masking tape after use.

3) When installing the cutting head onto the machine tool, check the interference between the fiber and the rubber plate at the Z-axis cable carrier.

Figure 3-2 Sealing of Q+connector (for reference only)

The detailed sealing steps can be found in the document "Q + Connector Standard Sealing Operating Instruction".

3.3.3 Replacing Upper/Lower Protective Lens

Notes:

1) Be sure to operate in a clean environment!

2) Before pulling out the protective lens component, use alcohol to clean the periphery of the upper protective lens component and make sure to operate in a dust-free environment.

3)Operate slowly and steadily to prevent the protective lens component from hitting the side wall.

4) After pulling out the protective lens component, immediately seal the opening of the cutting head chamber to prevent chamber contamination.

5) Check whether the upper protective lens is contaminated (only trained professionals are allowed to replace the optical fiber). All parts mounted on the optical path inside the laser head must be handled with care.

6) If the protective lens cannot be cleaned thoroughly or is damaged, contact the after-sales engineer to replace it.

Figure 3-3 Wearing part (for reference only)

Upper protective and collimation protective lens component

1. Loosen the locking screws, remove the cover plate and the upper protective lens component.

Figure 3-4

2. pull out the Collimation protective lens component.

Figure 3-5

3. Loosen the screws and disassemble the protective lens component.<br>Figure 3-6 Upper protective and collimation protective lens component

Focusing lower and lower protective lens component

1. Loosen the locking screws and open the protective cover plate.

Figure 3-7<br>Figure 3-8

2. Pull out the protective lens component.

Figure 3-9

3. Disassemble the protective lens component.

Figure 3-10 Focusing lower and lower protective lens component

You are advised to check whether the protective lens is stained when inserting the fiber.

Make sure the workplace is clean.

The laser head should be maintained and repaired only on a clean worktable. Do not allow dust and pollution source particles to enter the laser head. Dust and stubborn dirt could damage the optical parts.

3.3.4 Connector Definition

Figure 3-11 Definition of cutting head connector (for reference only)

X1: Diagram of 4P connector

X2: Diagram of 12P connector

Intelligent sP connector

Figure 3-15 Definition of Intelligent wire connector (for reference only)

Chapter 4 Debugging

4.1 Safety Precautions

4.2 W-axis Adjustment Setting (suitable for PA system or Beckhoff system with automatic focusing module)

W-axis stroke range: -7.5mm\~+7.5mm (A-CUTTER signal input low level)

Corresponding formula:

6-8KW is based on the provided focus formula y=0.001187x²+0.2507x+0.02984, and is described in conjunction with the automatic focusing board control module.

M\_Focus\_Shift is the W-axis mechanical position of the focus, and M\_Focus\_Shift\_Set is the set focus.

M\_Focus\_COP is the offset mechanical position of the set focus, and M\_Focus\_Shift\_offset is the offset value of the set focus.

M\_Focus\_SET is the total moving mechanical positions. M\_FOcUS is the voltage output to the focusing board after calculation.

Example procedures:

If M\_Focus\_Shift\_offset=0 (The focus offset is not included in the calculation if it is zero)

THEN

M\_Focus\_Shift:=(0.001187\*M\_Focus\_Shift\_Set+0.2507)\*M\_Focus\_Shift\_Set+0.02984 (Focusing formula)

M\_FOCUS:=REAL\_TO\_INT((0.5\*M\_Focus\_Shift+5)\*3276); (Calculate the output voltage) ELSE

M\_Focus\_Shift:=(0.001187\*M\_Focus\_Shift\_Set+0.2507)\*M\_Focus\_Shift\_Set+0.02984; (Focusing formula)

M\_Focus\_COP:=(0.001187\*M\_Focus\_Shift\_offset+0.2507)\*M\_Focus\_Shift\_offset +0.02984; (The focus offset formula, like the focusing formula, differs in the variables. The distance between the origin switch and the zero focus position shall be calculated)

4.4 Coaxial Adjustment

Figure 4-1 Coaxial adjustment (for reference only)

4.5 Verticality Assembly Requirements

Figure 4-2 Verticality Adjustment (for reference only)

Assembly Requirements!

Ensure the verticality relative to the working platform is within 0.1mm.

Recommended assembly method:

Use the diagonal method to assemble the screws to reduce the left and right deviation of the cutting head. Tighten the mounting screws so that the cutting head is in close contact with the mounting table.

Recommended test method:

Fix the measuring instrument on the working platform, move the cutting head, and measure the verticality of the upper surface of the gas path back plate and the side of W-axis component.

(The above method is based on the premise that Zaxis slide table meets the assembly requirements)

Figure 4-4 Assembly of the cutting Head (for reference only)

Chapter 5 Maintenance

5.3 Protective Lens Replacement

a) Do not touch the surface of optical lenses (protective lens, focusing lens, etc.), otherwise the surface will be easily scratched or corroded. Oil or dust on the lens surface will greatly affect the normal use of lens, therefore, clean the lens in a timely manner.

b) The surface of optical lenses is coated with a special film. Do not clean optical lenses with water or detergent, otherwise the lens surface could be damaged.

c) Do not place lenses in a dark, damp place, as this could age the lens surface.

d)The lens surface must be cleaned. If contaminated with dust, dirt or moisture, the lens surface will easily absorb laser and damage the lens coating, which will affect beam quality, or even prevent the laser beams from passing through or reflecting.

e) Do not apply too much force when installing or replacing the protective lens, or the lens will deform and beam quality will be adversely affected.

f) When replacing the protective lens of cutting head, make sure the installation positions and directions of all sealing elements are correct; otherwise, the interior of the cutting head could be contaminated.

g)Please install optical lenses in a clean environment: wear clean clothes, wash your hands with soap or detergent, and wear light, clean rubber gloves or finger cots. DO NOT touch the lens with your hands. When removing the lens, please take it from the side, instead of directly touching the lens surface.

h) Do not blow the lens with mouth during the process of installation. Place the lens on a clean table with a lint-free cloth underneath. Be careful when removing the lens, so as to avoid collision or falls. When flipping the cover, fix the lens holder with one hand, hold the cover lug with the other hand, and do not apply any force onto the coated surface of the lens. After opening the cover, remove the old protective lens. Check to see if the spring-loaded seal ring and the Teflon gasket need to be replaced (they must be replaced after 3 months of use or when any damage is found). The lens holder on which the lens is mounted should be clean. Use clean compressed air and alcohol swab to remove any dirt from the lens holder, place the lens gently into the lens holder. Then fasten the cover, press it gently, so that the cover snaps on the ball plunger.

i) When installing the spring-loaded seal ring and Teflon gasket, ensure that the arc end face of the gasket faces outward.

j)Replace the spring-loaded seal ring and Teflon gasket every 3 months.

k)Replace damaged sealing rings (spring-loaded seal ring and Teflon gasket) immediately.

I) When servicing the cutting head, use original accessories, as other accessories may have quality problems.

m)The replacement of the upper and lower protective lens components is shown in Section 3.3.3.

Note: The upper and lower protective lens components, beam expander component, focusing component and focusing protective component (The component mounting position can be referred to Figure 2-1) must be replaced by professionally trained and authorized personnel!

5.4 Cutting Head Troubleshooting

A. If there are still cutting quality problems after cutting parameters are modified, or there are black spots in the red light, do the following:

(1) Check whether the water path and gas path are normal;

(2)Clean or replace the protective lens if there are black burnt spots on it;

(3)Check to ensure the focus and the beam aperture of the cutting nozzle are coaxial;

(4)Please contact our after-sales engineers if the quality problems cannot be solved.

B. The user can also contact our engineers when the following problems occur:

(1)W-axis coordinate does not change when the machine returns to the reference point;

(2) When focus position is set in cutting parameters (but the focus is not in place), the next step (piercing or cutting) is started;

(3) The position of W-axis shows no change when focus position is changed;

(4) Other exceptions.

5.5 Caution

1. This cutting head can be maintained and repaired only by professionally trained and authorized personnel!

2. Harmful fumes that may be generated during the process of cutting should be discharged in a timely manner!

Appendix A: Consumables List