Chapter 2 Assembly and installation 22-50-17-CRen 2020-01 Assembly and installation 2‐3 1 Integration into a system environment 2‐4 1.1 Fastening 2‐4 1.2 Clearances 2‐6 1.3 Example 2‐7 2 Electrical insulation 2‐10 2.1 Measuring the insulation resistance 2‐11 3 Installation 2‐12 3.1 Overview of the connections 2‐12 3.2 Principles, general rules 2‐14 3.
3.4 Information required to assess the safety of a combination 2‐17 Examples of safe combinations 2‐19 Connection of the laser light cable (LLK) 2‐20 Connecting the laser light cable to the focusing optics 3.5 Connections for cooling unit 2‐26 3.6 Connections for crossjet, purging gas and MVE gas 2‐30 3.7 Connection for proximity switch (BEO D50 only, without protective glass monitoring unit) 2‐34 3.8 Lighting connection 2‐35 3.9 Connection for line laser 2‐36 3.
Assembly and installation Commissioning of the focusing optics: ■ ■ is done by a service engineer of TRUMPF during the commissioning of a laser device, if the focusing optics is delivered together with a laser device. is done by the user after start-up of an existing laser device, if you purchased the focusing optics afterwards. The following conditions must be fulfilled: ■ ■ ■ ■ 22-50-17-CRen 2020-01 The necessary safety equipment must have been installed and must be ready for operation.
1. Integration into a system environment The focusing optics is composed by modules according to the requirements of your application. This means that each focusing optics has different specifications: ■ ■ ■ Documents for the dimensions of the focusing optics for the fastening of the focusing optics. for the spaces which have to be kept free around the focusing optics.
Note The focusing optics BEO D50 Smart must always be fastened so that they are electrically insulated. Fastening elements To fasten focusing optics to a robot, a DIN-ISO connection plate is available. A fastening plate D50 - D70 is also available for fastening focusing optics D50 compatibly with focusing optics D70. For insulated fastening, there is an insulated fastening plate, D50 - D70.
"d" is a reference to the installation instructions, document no.: 22-50-17-A1-DH, the dimensional drawing for the bores "0° cube". Dimensional drawing for "d" in the installation instructions 1.2 Fig. 2-2 Clearances Keep free the environment around the focusing optics for the following: ■ ■ ■ ■ Unimpeded emission of the laser light. Compliance with the working distance at different focal lengths of lens. for adjustment work: − for aligning the focusing optics. − for adjusting the focal position.
Specifications for clearances to be observed Specifications for clearances which have to be observed are given in the following documents: ■ ■ in the dimensional drawing of the focusing optics in the installation instructions for focusing optics D50, doc. no.: 22-50-17-A1-DH. The example in the next section gives information on the meaning of the letters in the dimensional drawing and which specifications are to be found in the installation guideline. 1.
The installation instruction 22-50-17-A1-DH for focusing optics D50 supplements the dimensional drawing with important notes and dimensional information to be observed when installing the focusing optics in machines and devices. The areas and single components in the dimensional drawing which are marked with a letter are described in detail in the installation directive. Letters used Below you find a short summary of the letters used in dimensional drawings and information on their meaning.
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ [p] Plug receptacle A with defocusing. Notes on the bending radius LLK-A, insertion depth, fuse and space requirements for adjustment work. [a] Plug receptacle A and LLK-type. Information on space required for adjustment work. [r] Cover plate. Information on the space required for maintenance work. [s] Cooling water lines. Note on connecting the cooling water lines. [t] Insulated fastening plate D50 - D70.
2. Electrical insulation The mounting surface on the insulated fastening plate D50 D70 of focusing optics BEO D50 Smart is made of electrically insulating material. Notes ■ When mounting the focusing optics, please ensure that there is no electrically conductive connection between the casing of the focusing optics and the mounting frame. An electrical component or device may only be mounted to the focusing optics BEO D50 Smart in such a way that the potential of the focusing optics is not modified.
2.1 Measuring the insulation resistance Condition ■ Mounting of the focusing optics is completed. Measuring the insulation resistance Fig. 2-4 1. Unplug the plug-in connectors from the connections. 2. Measure the insulation resistance between casing of the focusing optics and the mounting frame. The resistance must be > 1 MΩ.
1 3. Installation 3.
1 Connection for laser light cable (LLK-D) 5 Connection for MVE gas 8 Purging gas connection 6 Purging gas connection 9 2 Cooling water connections for plug (LLK-D) 7 Connection for the crossjet Air supply connection for crossjet 3 Cooling water connections on the cooling water monitoring module 4 Shielding gas connection 10 Connection for MDE nozzle Connections on focusing optics BEO D50 Smart Fig.
3.2 Principles, general rules Laser light is a versatile tool of industrial material processing. The technology of solid-state lasers combines two advantages: ■ ■ Solid-state lasers can reach kilowatts in the double-digit range, also as continuous wave. The light of the solid-state lasers can be guided and formed by means of glass optics (lenses, mirrors, prisms and fiber glass). But the advantages have their price: The higher the laser power used, the higher are the demands on cleanliness.
Make sure that the plug receptacles and the LLK plugs are unprotected only during connection and disconnection. Never touch the surfaces of the optical components with your fingers. 3.
DANGER Housing of focusing optics gets hot! Touching the focusing optics can lead to serious burns. Ø Only use safe combinations of laser device, laser light cable and focusing optics. Numerical apertures cannot be combined Numerical aperture of the focusing optics is too small If the numerical aperture of the focusing optics is smaller than the numerical aperture on the decoupling connector, a part of the laser light hits the aperture of the focusing optics.
Focusing optics is not designed for the rated power of the laser device Rated power of the laser device is too high A focusing optics will be damaged if it is operated with a higher power than that which is specified. The housing of the focusing optics can heat up strongly (> 300 °C). The following dangers result from this: ■ ■ ■ Fire hazard: Materials in the environment of the focusing optics can catch fire. Risk of burns: People who work with the focusing optics may suffer burns.
Information on the incoupling optics (example TruDisk FD27) Information on the laser light cable (examples) Fig. 2-8 Information on the permissible wavelength spectrum and the permissible numerical aperture are to be indicated on the incoupling connector and on the outcoupling connector. The nameplate contains additional information about the laser light cable.
1 Information on the incoupling connector 2 Information on the outcoupling connector Information on LLK-D NA0067/015-01 HP Information on the focusing optics Fig. 2-12 The processing optics contains information on power, numerical aperture and wavelength spectrum on the plug receptacle. Fig.
3.4 Laser light cable Connection of the laser light cable (LLK) In the case of focusing optics BEO D50 Basic, the laser light cable LLK-A, laser light cable LLK-B (using an adapter) or laser light cable LLK-D is used. In the case of focusing optics BEO D50 Smart, only laser light cable LLK-D is used. LLK-A 1 3 1 Plug receptacle 2 Optical plug of the laser light cable 3 CT-00454 2 Locking screw LLK-A Fig.
LLK protection 1 Plug receptacle LLK-D 2 Optical plug of the laser light cable LLK-D 3 Adhesive tape, 19 mm Fig. 2-16 Note To protect the LLK from dirt, TRUMPF recommends sealing the disconnection point between the LLK plug and the plug receptacle of the focusing optics with adhesive tape. In a contaminated environment (e. g. dust, oil vapor), TRUMPF recommends the additional use of a protective sleeve.
Installing the laser light cables Ensure that the laser light cables are installed without tensile stress, buckles and torsion-free. bend radius The bend radius of the laser light cable must not be smaller than 200 mm. Connecting the laser light cable to the focusing optics The following instructions describe how to proceed step-by-step when connecting an LLK to a focusing optics. In the following instructions, we assume that the optics cannot be rotated on the carrier.
Dirt in beam path! NOTICE This may destroy the LLK or focusing optics. Ø Ø CT-00420 Ø Leave openings on LLK and focusing optics unprotected as short as possible. Put the shaft of the plug receptacle in horizontal position as long as the plug receptacle of the focusing optics is open. Do not touch optical surfaces. Plug receptacle and LLK (sealed with adhesive tape) Fig. 2-17 CT-00421 1. Store the focusing optics such that the shaft of the plug receptacle for the LLK is in a horizontal position.
Remove the protective cap from the LLK plug Fig. 2-19 5. Remove the adhesive tape from the LLK plug (1). 6. Remove the protective cap from the LLK plug. by turning protective cap to the left (bayonet locking) (2) and (3). 2. 1. CT-00423 3. Fig. 2-20 Steps for mounting CT-00424 7. Immediately plug in the plug of the LLK in the plug receptacle of the focusing optics (1). 8. Turn the sliding sleeve (2) as shown on the applied engraving 5° to the right until this locks. 9.
10. Join sealing plug and protective cap and store them carefully. Both parts will be needed when you separate the focusing optics and the LLK again. 0260-47-T 11. Mount the focusing optics to the support. 12. If any, establish all other connections to the focusing optics (electrical plugs, cooling water hoses). 13. Lay LLK and other connected lines such that they have sufficient room for movement. 1 Adhesive type 2 Sealing plug and protective cap 3 Focusing optics Mounted protective sleeve Fig.
3.5 Connections for cooling unit 2 1 CT-00457 2 1 1 Supply connection 2 Connection, return Connections on the BEO D50 Basic plug receptacle Fig. 2-23 One pair of hoses, supply and return (black/red hose set), supply the focusing optics with cooling water. When using an LLKD, the optical plug is also cooled with water. The cooling lines are already fully installed on the focusing optics. Only the connection for the cooling water supply and for the LLK are still missing.
BEO D50 Smart 1 In the case of focusing optics BEO D50 Smart, the cooling water temperature can be monitored within preset limits via the cooling water monitoring module. For more information on this topic, please refer to the software manual of the controlled focusing optics. Supply connection (at the cooling water monitoring module) 2 Return connection (at LLK plug) Connections at the BEO D50 Smart plug receptacle Additional cooling Fig.
1 Supply 4 Focusing lens 7 Collimation 2 Return 5 Plug receptacle Connecting hose Cooling ring plug receptacle LLK-A with defocusing 8 3 6 Cooling block on the cube Hose system (examples) Cooling water hoses Fig. 2-25 The length of the cooling water hoses is adapted to the selected laser light cable. The connections at the focusing optics are automatically acting couplings. The following cooling water hose is used: ■ ■ Outside diameter 6 mm. Inside diameter 4 mm.
Cooling water Normally the cooling water of the laser device is also used to cool the focusing optics. Cooling water contains DI water enriched with anticorrosives! CAUTION Ø Ø Ø Ø Ø Cooling water for external cooling Wear safety glasses and disposable gloves. Protect clothing from contact with cooling water. Keep cooling water away from eyes and mouth. Flush eyes and mouth immediately with drinking water to remove any cooling water.
3.6 Connections for crossjet, purging gas and MVE gas 1 Crossjet 4 Connection for MDE nozzle 2 Purging gas connection 5 Outflowing MVE gas 3 Air supply connection for crossjet Connections on BEO D50 Basic crossjet 2‐30 Installation 2020-01 Fig.
1 Crossjet 6 2 Purging gas connection Connection for shielding gas at the gas monitoring module 3 Connection for MVE gas at the gas monitoring module 4 Air supply connection for cross- 7 jet 8 Connection for MDE nozzle 5 Outflowing MVE gas 9 Connection for purging gas at the gas monitoring module Connection for crossjet supply air at the gas monitoring module Connections on BEO D50 Smart crossjet Hot surfaces on the crossjet can burn your skin! CAUTION If the crossjet is bent (e.g.
Note In the case of focusing optics BEO D50 Smart, the flow of the process media (purging gas, MVE gas, shielding gas and the crossjet pressure) can be monitored within adjustable limits via the gas monitoring module. For more information on this topic, please refer to the software manual of the controlled focusing optics. Crossjet Cleaned and dried compressed air is used as supplied air. Focal length of lens f150 Focal length of lens ≥ f200 Gap width 0.5 mm 0.3 mm Pressure approx. 5 bar approx. 3.
(plasma torch). This may lead to welding depth fluctuations and to irregular weld surfaces. Cleaned and dried compressed air according to DIN ISO 8573-1 is supplied toward the processing plane via the connection for the MDE nozzle. The air flow of the MDE nozzle eliminates the plasma torch. ct-00299 2 1 Plasma torch with and without use of coaxial MDE nozzle Hose outer diameter 6 mm Air consumption approx. 35 l/min Fig. 2-28 (focal length of lens f150) Air consumption approx.
3.7 1 Connection for proximity switch (BEO D50 only, without protective glass monitoring unit) Connector of proximity switch, 3-pole, M8 x 1 2 Protective glass cassette 3 Cartridge holder 4 Proximity switch 5 Sensor block Connection proximity switch protective glass cassette Fig. 2-29 The proximity switch must in all cases be connected for safe operation of the focusing optics and indicates whether a cassette is present or not.
1 0 V 2 +Vs 3 Output signal Proximity switch plug terminal assignment Proximity switch connection data Operating voltage range +Vs: 10 - 30 V DC Max. current consumption (without load): 12 mA Operating voltage: 24 V DC. ■ ■ ■ Signal level at output A Fig. 2-30 Protective glass cassette available: 24 V Protective glass cassette not available: 0 V ■ ■ 3.8 Lighting connection The processing point lighting is supplied with 24 V. Fig.
3.9 Connection for line laser The line laser is supplied with 24 V. Connection for line laser, M8 connector Pin Supply line Designation Note 1 Brown +24 V Power supply: 3 Blue GND Central earth 4 Black TRIGGER On: high level +24 V X1 – Connection for line laser, M8 connector, 3-pin Fig. 2-32 Tab. 2-7 Note The line laser can also be controlled via the image processing software VisionLine; see the operator's manual "VisionLine", doc. no.: 22-50-12-A0-CR. 3.
3.11 Other BEO D50 Smart connections Interface module 1 Plug X2 Interface of other components 2 Plug X4 Interface of other components 3 Flange plug X10 Laser device interface 4 Screw-in socket Connections on the BEO D50 Smart interface module Fig. 2-33 The area marked in the dimensional drawing must be kept free for the connectors. Connector (1) comes from the IIO board of the laser device and must be able to be manually inserted into/removed from the flange plug (3) of the interface module.
bend radius of the cable (Rmin = 80 mm) may not be fallen short of if the focusing optics is subjected to dynamic movements. The plug-in length is 9 mm. Connector (2) comes from the protective glass monitoring unit or another electrical component on the focusing optics and must be able to be manually inserted into/removed from the built-in socket (4) of the interface module. Here, the permissible bend radius of the cable (Rmin = 80 mm) may not be fallen short of. The plug-in length is 6 mm.
Gas monitoring module 1 Connection for shielding gas (Ø8) 3 Connection for purging gas (Ø8) 2 Connection for MVE gas (Ø8) 4 Connection for crossjet supply air (Ø12) BEO D50 Smart gas monitoring module Fig. 2-35 The area marked in the dimensional drawing must be kept free for the media feed (supply air). The supply interface is equipped with quick-acting couplings, which are marked (1) - (4).
4. Ambient conditions Temperature Relative humidity Operation: +15 °C – +40 °C Storage: +5 °C – +40 °C at 40 °C: max. 40 % at 20 °C: max. 90 % Protection type: IP 50 Maximum acceleration: 3 g with 5 – 150 Hz Tab. 2-8 The focusing optics must not be operated in an explosion endangered environment. Cooling water temperature If hot and humid air contacts the cold surfaces, condensate is formed at certain temperatures.
Determining the necessary cooling water temperature SG-02007 dew point temperature in °C 4.1 ambient temperature in °C Dew point diagram Fig. 2-36 1. Measure ambient temperature (in the example: 36 °C). 2. Measure the relative humidity (80 % in the example). 3. Draw a vertical line in the diagram from the measured ambient temperature upwards until it intersects with the straight line representing the measured humidity. 4.
5. Using shielding gas 5.1 Gases during laser welding During laser welding, gases are used in order to improve the results and avoid deposits on the laser tools. According to the type of use, a distinction is made between ■ ■ ■ Assist gas (MDE gas) Inert gas Crossjet gas Assist gases are helpful when welding with Nd:YAG lasers. They suppress the absorption of laser light in the plasma of the metal vapor.
components of air and has a positive effect on the quality of the welding seam. 5.3 Shielding gases For laser welding metals, mainly inert (inactive) gases are used. Inert gases do not react with the base material or only to a very limited extent. Recommended shielding gases are: ■ Nitrogen (N2) ■ Argon (Ar) Helium (He) ■ Purity of the gas Industrially produced gases always contain a small amount of impurities. The purity of the gases is indicated by a system of digits.
Nitrogen (N2) Nitrogen is a colorless, odorless and inert gas. Nitrogen is suitable for the welding of chromium nickel steel. It is not suitable for use with zircaloy and titan materials because it can combine with these materials despite its inertness. When welding steel with nitrogen it should be considered that the nitrogen lowers the stainless protection by removing the chrome-nickel components from the steel.
Aluminum and aluminum alloys Ar He N2 Remarks - + - Smooth and polished weld seams are produced with helium or a helium mix. The use of argon causes blowholes in the material. Hydrogen gases cause blowholes in the material. High-quality weld seams can be produced with carbon dioxide (CO2) or a helium-carbon dioxide mix. However, the weld seams are less smooth and polished.
Linear gas supply The linear nozzle is a further development of the multiple tube, where the individual tubes are consolidated. The linear nozzle has the following advantages: ■ ■ ■ Better welding seam quality. Smaller interference contour thanks to compact structure. Can also be used if there is a greater distance between the nozzle and workpiece. Prerequisites: ■ ■ 1 cw laser device. Focal length of lens f = 150 mm, f = 200 mm, f = 250 mm and f = 300 mm. Linear nozzle Fig.
Shielding gas hose The following shielding gas hose must be connected to the fitting: ■ ■ Outside diameter: 8 mm Inside diameter: 6 mm Linear gas supply with a lateral MDE nozzle Using this nozzle, linear supply of the protective gas is possible while, at the same time, metal vapor effect can be eliminated with a lateral MDE nozzle. Prerequisites: ■ ■ cw laser device. Focal length of lens f = 150 mm, f = 200 mm, f = 250 mm and f = 300 mm.
Note The crossjet effect might be impaired, depending on the positioning of the linear nozzle. Shielding gas hose The following shielding gas hose must be connected to the fitting: ■ ■ Outside diameter: 6 mm Inside diameter: 4 mm If a lateral MVE nozzle is installed, the hose of the MVE nozzle must be terminated and connected to the lateral MVE nozzle: ■ ■ Outside diameter: 6 mm Inside diameter: 4 mm Aerator nozzle gas supply The conical nozzle contains an aerator.
Depending on the application, a distance of 8 to 12 mm is recommended at a 30° to 50° angle to the workpiece. 1 Nozzle locking screw 2 Vertical and horizontal clamping screw setting Fig. 2-41 Aerator nozzle The laminar-flow nozzle can be fastened to the crossjet receptacle. For more detailed information, see the dimensional drawing, doc. no. 22-51-01-A34-BX. The distance to the focusing optics and the angle to the workpiece can be adjusted as required (1 and 2).
5.5 Arrangement of the shielding gas nozzles For laser welding, a distinction is made between two welding processes: ■ ■ Thermal conduction welding Deep welding With thermal conduction welding, the material is melted at the surface only. Welding seams of some tenth of millimeters depth are produced. This method is especially common with pulsed Nd:YAG laser With penetration welding, however, very deep and very narrow welds are produced. Penetration welding is done with Nd:YAGlasers in cw mode.
1 0011 2 1 Wire 2 Shielding gas supply Fig. 2-43 cw lasers In order to achieve optimum results with cw laser devices, the shielding gas is always supplied trailing and the wire supply (if used) leading. 1 0010 2 1 Wire 2 Shielding gas supply Fig.
Welding at edges The nozzles of the shielding gas supply line must be arranged in a way that a laminar, constant gas flow is produced. Especially welding at edges can cause swirls that move the oxygen of the surroundings to the weld point. The material can already react with the oxygen if the oxygen portion > 0.5 %. If welding is performed on edges, a swirl of the gas flow can be prevented by attaching a deflector. 3 3 4 2 0013 1 1 Workpiece 3 Laser beam 2 Deflector 4 Shielding gas nozzles Fig.
0023 Turbulent gas flow: High gas pressure, air is taken in. Laminar gas flow: Low gas pressure; without inflow of air Fig. 2-46 The color of the welding seam allows a statement about the amount of the used shielding gas. 0020 From a gray discoloration of the welding seam can be concluded that no shielding gas was used. If the welding seam yellows, the dose must be optimized further. A high gloss seam is produced when the shielding gas is dosed optimally.
0022 Fig. 2-48 Weld seam: shielding gas optimally dosed, even, high-gloss seam. Fig. 2-49 0021 Weld seam: yellow color zones in the seam (bright areas in the picture); dosing must be optimized further. A shielding gas nozzle with perlator ensures an even outflow of shielding gas. The same effect can be created with steel wool in the nozzle.
0014 LASER Laminar flow Fig. 2-50 For welding applications with a strong production of splashes and vapor, a crossjet can be used. The crossjet must be adjusted to allow the shielding gas to flow unaffected by the crossjet gas. Crossjet Tip With a simple test, it can be checked if the crossjet was adjusted optimally: Keep a paper strip over the workpiece and adjust the gas pressure to such a level that the paper strip is not pushed down or drawn in by the crossjet. 5.
Argon (Ar) Helium (He) Nitrogen (N2) without shielding gas Spatter + + 0 - Pores ++ + + - Incoupling laser light - - - + Costs - - 0 + Effect of the shielding gases: + = favorable, 0 = neutral, - = unfavorable Tab. 2-11 Note To optimize the effect of the shielding gas, the shielding gas must have been switched on briefly before starting and remain switched on after finishing welding. After being switched on, the shielding gas takes some time to reach the workpiece.
