Chapter 3 Description 22-50-17-CRen 2020-01 1 Models and options 3‐3 1.1 Minimum configuration 3‐3 1.2 Available modules 3‐4 2 Components 3‐6 2.1 Focusing optics module overview 3‐6 2.2 Requirements 3‐13 2.3 Collimator with plug receptacle 3‐14 2.4 Protective sleeve 3‐16 2.5 Dual focus optics 3‐17 2.6 Connecting piece 3‐18 2.7 BEO D50 Smart interface module 3‐19 2.8 Observation optics 3‐20 2.9 Pyrometer outlet 3‐22 2.10 Interface for sensor module 3‐23 2.
.14 3‐2 Description Lenses for welding 3‐26 BEO D50 Smart cassette receptacle with protective glass cassettes 3‐30 Crossjet and MVE nozzle 3‐32 2.15 Connection plates 3‐34 2.16 Focusing optics examples 3‐36 3 Functional description 3‐41 3.1 Beam guideway of the laser light 3‐41 3.2 Beam guideway in the observation optics 3‐46 3.
1. Models and options The focusing optics has a modular design. Various modular system components can be combined, depending on the application. Special applications may require special models. 1.1 Minimum configuration 1 2 3 4 5 6 CT-00464 7 1 Plug receptacle 5 Lens 2 Collimation 6 Focusing lens 3 Collimation lens 7 Lens protection 4 Empty cube extension Minimum configuration of a focusing optics D50 with drawnin beam path 22-50-17-CRen 2020-01 Models and options Fig.
Laser light Laser light is generated in the laser device and coupled into the laser light cable. Plug receptacle with defocusing Plug receptacle (1) is for mounting the optical plug of the LLK. Empty cube extension The collimation is connected to the objective (4) via the empty cube extension (5). Lens Lens protection Conical laser light is emitted from the LLK. The collimator lens (3) forms the collimated laser beam from this, which runs virtually parallel.
■ ■ ■ ■ ■ and sensor block (proximity switch for presence of process protective glass cassette). − BEO D50 Smart cassette receptacle with objective protective glass cassette and process protective glass cassette and protective glass monitoring module. − Lens protection receptacle with protective glass holder. − Crossjet f150-f300. Optional modules for BEO D50 Smart. − Interface module (incl. cooling water monitoring module) − Gas monitoring module Coaxial lighting. Observation optics.
2. Components In the following section you will find: ■ ■ the various demands on the focusing optics. a description of the various focusing optics modules. 2.1 Modular system Focusing optics module overview Focusing optics are composed of modules according to the requirements of the respective processing task. The following figures show the most important modules available for focusing optics.
Module overview for BEO D50 Basic 0° and 90° 1 2 Plug receptacle A with defocusing, focal length f35 8 Bifocal optics 15 Fastening plate D50 - D70 9 External lighting 16 Lens Plug receptacle D with defocusing, focal length f35 10 Empty cube 17 Sensor block 11 0° cube 12 Lighting module 18 Cassette holder with protective glass cassettes 13 Observation optics 19 Lens protection 14 Interface for sensor system 20 Crossjet 3 Plug receptacle A 4 Plug receptacle D 5 Adapter LLK-B on LLK-D 6
1 2 Plug receptacle A with defocusing, focal length f35 8 Bifocal optics 14 Interface for sensor system 9 External lighting 15 Lens Plug receptacle D with defocusing, focal length f35 10 Lighting module 16 Sensor block 11 90° cube 12 Fastening plate D50 - D70 17 Cassette holder with protective glass cassettes 13 Observation optics 18 Lens protection 3 Plug receptacle A 4 Plug receptacle D 5 Adapter LLK-B on LLK-D 6 X-Y offset 7 Collimator with cooling block 19 Crossjet Module overv
BEO D50 Basic with 2 x 90° double deflection 1 2 Plug receptacle A with defocusing, focal length f35 8 Bifocal optics 14 Fastening plate D50 - D70 9 Interface for sensor system 15 Lens Plug receptacle D with defocusing, focal length f35 10 Observation optics 16 Sensor block 11 Lighting module 12 2 x 90° double deflection 17 Cassette holder with protective glass cassettes 13 External lighting 18 Lens protection 3 Plug receptacle A 4 Plug receptacle D 5 Adapter LLK-B on LLK-D 6 X-Y offs
Module overview for BEO D50 Smart 0° and 90° 1 Plug receptacle D SCL 9 2 Adapter LLK-B on LLK-D 10 Bifocal optics Cooling block 3 Extension piece 11 External lighting 17 Insulated fastening plate D50 D70 4 X-Y offset 12 Empty cube 18 Lens 5 Gas monitoring module 13 0° cube 6 Collimation 14 Lighting module 19 Cassette holder with protective glass cassettes 7 Cooling water monitoring module 15 Observation optics 8 Interface module Module overview, focusing optics BEO D50 Smart 0°
1 Plug receptacle D SCL 8 Interface module 15 External lighting 2 Adapter LLK-B on LLK-D 9 Cooling block 3 Extension piece 10 Bifocal optics 16 Insulated fastening plate D50 D70 4 X-Y offset 11 90° cube 17 Lens 5 Gas monitoring module 12 Lighting module 6 Collimation 13 Observation optics 18 Cassette holder with protective glass cassettes 7 Cooling water monitoring module 14 Interface for sensor system 19 Protective glass monitoring module 20 Sensor block 21 Crossjet Module overv
BEO D50 Smart with 2 x 90° double deflection 1 Plug receptacle D SCL 8 Interface module 15 External lighting 2 Adapter LLK-B on LLK-D 9 Cooling block 3 Extension piece 10 Interface for sensor system 16 Insulated fastening plate D50 D70 4 X-Y offset 11 Observation optics 17 Lens 5 Gas monitoring module 12 Lighting module 6 Collimation 13 Bifocal optics 18 Cassette holder with protective glass cassettes 7 Cooling water monitoring module 14 2 x 90° double deflection 19 Crossjet 20 P
2.2 Focal lengths Depending on the machining task, lenses with various focal lengths are used. The focal length of lens has an effect on ■ ■ ■ Wavelengths Requirements the working distance between lens and workpiece. the beam diameter and thus the power density at the machining point. the depth of focus and consequently on the machining depth in the workpiece. The focusing optics can be operated within different wavelength spectrums.
Observation options Focusing optics offer different observation methods: ■ Geometry Focusing optics are available in two designs: ■ ■ Two weld points, two weld seams Special constructions Camera for constant monitoring of the machining process. straight version (0°). angled version (90°). Dual focus optics can be used for simultaneous application of two weld points or two welding seams next to each other. Special constructions are possible for special applications. 2.
The plug receptacle of the focusing optics is available in various versions: ■ ■ ■ ■ Plug receptacle A with length f35. Plug receptacle A with length f100 and f125 Plug receptacle D with length f35 Plug receptacle D with length f100 and f125 defocusing, for LLK-A with focal collimation, for LLK-A with focal defocusing, for LLK-D with focal collimation, for LLK-D with focal The LLK-B is inserted into plug receptacle D with an adapter. Notes ■ ■ Focusing optics BEO D50 Smart can only be used with LLKD.
The collimation of focusing optics D50 has a focal length of 100 mm or 125 mm. The focal length of the collimation determines the dimensions of the focusing optics D50. Zero position Set ring If collimation is set to zero, the focus position will correspond to the details in the dimensional drawing. The focusing optics can be defocused by means of the setting ring.
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 (see chapter "Mounting and installation"). Note For sealing the disconnection point, use exclusively PVC adhesive tape, 19 mm, material no. 1420313.
Division of the power The bifocal optics of focusing optics D50 has a fixed set distance between the focal points and divides the laser beam into two partial beams of the same power. If the laser light cable was replaced, it may be necessary to adjust the power splitting of the dual focus optics (see "Adjusting the dual focus optics", pg. 4‐21). Location of the focal points c b 0030-68-R a 360° Fig.
Fastening methods Connecting pieces are used to fasten focusing optics to a support. Note In the case of focusing optics BEO D50 Smart, the fastening must be insulated. Separating plate and deflection mirror The 0° cube has a separating plate, the 90° cube has a deflection mirror. The 2 x 90° double deflection has two deflection mirrors. The laser light or the visible light for observation is deflected in the cubes. The empty cube extension however contains no optical element.
The temperature of the cooling water can be monitored within preset limits via the cooling water monitoring module. 2.8 Observation optics The observation optics is the intermediate piece between separating plate or deflection mirror on the one hand and the camera on the other. 1 camera 3 Deflection 2 Observation optics 4 Coaxial lighting Observation optics Fig. 3-15 The viewing optics consists of ■ ■ ■ a filter keeping away the laser light. a deflection mirror (90° version only).
Chip 4.85 mm x 3.65 mm Magnification Focal length of lens β = 0.4 β = 1 β = 2 150 mm 18.2 mm x 13.7 mm 7.28 mm x 5.48 mm 3.64 mm x 2.74 mm 200 mm 24.25 mm x 18.25 mm 9.7 mm x 7.3 mm 4.85 mm x 3.65 mm 250 mm 30.31 mm x 22.81 mm 12.1 mm x 9.1 mm 6.05 mm x 4.55 mm 300 mm 36.38 mm x 27.38 mm 14.55 mm x 10.95 mm 7.28 mm x 5.48 mm Visible section of the processing point on a TXG03 and TGX12 camera (digital output) Tab. 3-1 Chip 4.96 mm x 3.72 mm Magnification Focal length of lens β = 0.
2.9 1 Pyrometer outlet Pyrometer outlet 2 Deflection Pyrometer outlet Fig. 3-16 The pyrometer outlet is used to hold the pyrometer's optical fiber to enable temperature control. This is possible using the "Temperature Process Control Interface" technology package. For more information see the operator's manual for this, doc. no.: 20-50-01-A425-CR.
2.10 Interface for sensor module CT-00471 1 1 Safety screws Interface for sensor module, Example 90° Fig. 3-17 A sensor module for process monitoring is connected via this interface. The sensor module detects the laser radiation reflected by the workpiece and the radiation emitted from the machining point. There is no laser protective filter in the interface for the sensor module. Therefore use of the eyepiece or camera at this interface is not allowed.
2.11 Lighting module Fig. 3-18 The lighting module is used to light up the processing point during setup mode using a red light with a wavelength of 625 nm. CAUTION Rays from the lighting may cause damage to eyes! Looking directly into the rays from the lighting, which are reflected by mirrored surfaces, may result in glare. Ø Ø Attach a sign warning people about this danger. Brief any persons potentially at risk. The lighting is supplied with 24 V (see "Lighting connection", pg. 2‐35).
2.12 External lighting 1 Fastening options on the fastening plate D50 - D70 2 Fastening options on the cube Fig. 3-19 External lighting via the LED spot is used to light the processing point with a red light with a wavelength of 617 nm. This can be screwed onto the (insulated) fastening plate D50 D70 or onto the cube, and the spot orientation can be adjusted via an articulated arm.
2.13 Line laser 1 Clamping screw 4 Line laser 2 Laser module 5 3 Clamping holder, line laser Adjusting screw (linear adjustment) 6 Knurl for axial adjustment Line laser and removed laser module Fig. 3-20 The line laser together with the pilot laser are used to adjust the working distance in the setup mode. Depending on the setup of the processing optics, the line laser is installed either on the cube, on the crossjet or on the end plate.
4 3 CT-00472 2 1 1 Lens protection 3 Lens 2 Lens protection receptacle 4 Cooling water connections Lens with lens protection Fig. 3-21 1 Connection plate, crossjet 4 Purging gas connection 2 Lens 5 3 Objective protective glass cassette Process protective glass cassette Objective with cassette receptacle Fig. 3-22 The lens is sealed towards the workpiece: ■ Protective glass by means of a lens protection (see "Fig. 3-21", pg. 3‐27).
The cassette receptacle contains two protective glass cassettes: ■ ■ Process protective glass cassette. Objective protective glass cassette. The objective protective glass cassette protects the objective lens when the process protective glass cassette has been removed. The protective glass monitoring module is used on the BEO D50 with a protective glass monitoring unit (see "BEO D50 Smart cassette receptacle with protective glass cassettes", pg. 3‐30).
1 Supply 4 Focusing lens 7 Collimator f100 and f125 2 Return 5 Plug receptacle LLK-D Connecting hose Cooling ring for plug receptacle with defocusing f35 8 3 6 Objective with cooling block Hose system (examples) 22-50-17-CRen Fig.
BEO D50 Smart cassette receptacle with protective glass cassettes Fig. 3-24 The BEO D50 Smart cassette receptacle can be mounted on the objective in one of two positions (2 x 180°) as required. The cassette receptacle contains two protective glass cassettes: ■ ■ Process protective glass cassette. Objective protective glass cassette. The objective protective glass cassette protects the objective lens when the process protective glass cassette has been removed.
The following is measured and monitored: ■ ■ ■ ■ Protective glass contamination Cassette presence Use of correct protective glass Scattered light of protective glass A message is displayed on the screen of the operating PC if the contamination of the protective glass exceeds the permissible range set in TruControl 1000. In this case, the protective glass must be cleaned or replaced (see the "Maintenance" chapter).
NOTICE If the focusing optics is started following a fault message, without having eliminated the cause of the fault, laser light may be emitted from the focusing optics for a few milliseconds. This uncontrolled welding may destroy the workpiece. Ø Eliminate the fault on the focusing optics immediately. Crossjet and MVE nozzle A crossjet can be used on the cassette receptacle for welding applications with strong spatter and vapor formation.
When the air supply is switched on, the supply air needs some time to built up pressure in the crossjet. After finishing welding, smoke rises, which has to be deflected away from the protective glass. 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. 3.5 bar Air consumption approx. 500 l/min approx. 210 l/min Compressed air Tab.
the MDE nozzle. The air flow of the MDE nozzle eliminates the plasma torch. Hose diameter 6 mm Air consumption approx. 35 l/min (focal length of lens f150) Air consumption approx. 50 l/min (focal length of lens ≥ f200) Compressed air Tab. 3-5 The actually required pressure depends on the plasma torch of the respective welding application.
According to DIN ISO 9409-1, the DIN-ISO connection plate is provided with: ■ ■ a centering unit D 31.5 a pitch circle TK ∅ 50 for M6 screws and pin ∅ 6. KR30 connection plate 1 KR30 connection plate TK100 2 Cube with fastening plate D50 - D70 Accessories connection plate Fig. 3-27 Connection plate KR 30 TK100 has a pitch circle TK of ∅ 100 for M8 screws and a pin of ∅ 8. Fastening plate D50 - D70 (insulated) 1 Centering sleeves ZBH7 Fastening plate D50 - D70 with insulating plate Fig.
Note The focusing optics BEO D50 Smart must always be fastened so that they are electrically insulated. Accessories connection plate 1 Accessories connection plate 2 Fastening plate D50 - D70 Accessories connection plate Fig. 3-29 The connection plate for accessories is attached to fastening plate D50 - D70 and used for fastening accessory parts, such as external lighting. 2.
1 Lens protection 5 Connections for cooling unit 2 Lens 6 Plug receptacle LLK D 3 Empty cube 7 camera 4 Collimation 8 Observation optics for camera Focusing optics BEO D50 Basic, straight (0°) Fig. 3-30 The following figure shows straight (0°) focusing optics with plug receptacle D, cassette receptacle and crossjet. In this example, plug LLK-D, plug receptacle D, the collimator and the cassette receptacle are cooled.
1 Crossjet 5 Plug receptacle D 2 Cassette receptacle 6 Plug LLK-D 3 Lens 7 Cooling water supply 4 0° cube 8 Cooling water return Focusing optics BEO D50 Basic with cassette receptacle and crossjet 3‐38 Components 2020-01 Fig.
The following figure shows focusing optics BEO D50 Basic with 2 x 90° double deflection, crossjet, pyrometer outlet and a monitoring option using a camera. 1 Plug receptacle D 6 Lens 2 Collimator with cooling block 7 2 x 90° double deflection 3 Crossjet connection 8 Observation optics 4 Coaxial MVE nozzle connection 9 5 Cassette holder with protective glass cassettes camera 10 Pyrometer outlet Focusing optics BEO D50 Basic with 2 x 90° double deflection Fig.
1 Crossjet 5 Plug receptacle D SCL 2 Cassette receptacle 6 Plug LLK-D 3 Lens 7 Cooling water supply 4 0° cube 8 Cooling water return Focusing optics BEO D50 Smart with cassette receptacle and crossjet 3‐40 Components 2020-01 Fig.
3. Functional description 3.1 Beam guideway of the laser light 1 Optical plug of the laser light cable (LLK-D) 6 Focusing lens 7 Lens protection 2 End of the laser light cable 8 Focal point 3 Plug receptacle 9 Workpiece 4 Collimation lens 5 Lens Focusing optics D50, schematic diagram Fig. 3-34 Beam guidance In case of a beam guidance through the laser light cable, a conical laser beam comes out of the end of the laser light cable.
mation lens. Focusing optics D50 have a collimator with a collimation focal length fc = 125 mm, fc = 100 mm or fc = 35 mm as standard. Focal length of lens The focal length of lens f determines the distance between focusing lens and focal point. Lenses with the following focal lengths can be used in the focusing optics D50: ■ ■ ■ ■ f f f f = = = = 150 200 250 300 mm. mm. mm. mm. For information on special focal lengths, please contact TRUMPF.
4 fc 2 1 3 dk 5 f 0030-14-T d0f 1 Fiber 4 Observation 2 Collimation lens 5 Focusing lens 3 Deflection mirror Beam guideway in a 90° focusing optics Focal diameter Fig. 3-36 The diameter of the focused laser beam at the smallest point (waist) is called focal diameter d0f. Fig.
Aspect ratio The ratio of lens focal length f to collimation focal length fc is named aspect ratio β. Fig. 3-38 β: aspect ratio β > 1 means that d0f > dk β = 1 means that d0f = dk β < 1 means that d0f < dk Depth of focus The length of the optical axis in the focus where the focal diameter d0f changes only negligibly, is called depth of focus.
Long focal lengths of lens show the following advantages compared with short focal lengths of lens: ■ ■ Larger working distance. By this, less soiling of the lens protection as usually. The power density on the processing point will drop with increasing soiling. This diminishes the processing quality. The depth of focus is longer. This allows a larger working distance range without changed machining results.
3.2 1 camera 2 Observation optics 3 Beam guideway in the observation optics Separating plate 4 Deflection mirror 0° focusing optics (left) and 90° focusing optics (right) 3‐46 Functional description Fig.
1 Laser beam path 2 Beam path for observation optics 3 2 x 90° double deflection Beam path through the 2 x 90° double deflection Fig. 3-41 For viewing and adjustment of the workpiece, a separating plate or a deflection mirror is inserted into the beam path. Focusing optics 0° For a 0° focusing optics for monitoring, a separating plate is used. This separating plate is permeable to light with the wavelength of the laser beam.
from the workpiece to enter the viewing optics via the lens. The deflection mirrors deflect the light of the laser beam to the lens. Protective filter camera The observation optics is provided with a protective filter to avoid laser light being emitted from the observation optics. A camera can be attached to the observation optics. The camera is used to adjust and watch the machining point also during the machining process. The Operator's manual of the manufacturer contains information on the camera.
1 Cooling water hose – return 3 Laser light cable (LLK-D) 2 Cooling water hose – supply 4 Connecting cable, electronics Focusing optics BEO D50 Smart, connected to a laser device (diagram) Laser light Monitoring functions of the BEO D50 Smart Fig. 3-43 Laser light is generated in the laser device and coupled into the laser light cable.
3‐50 Functional description 2020-01 22-50-17-CRen
Chapter 4 Adjustment work 22-50-17-CRen 2020-01 General notes on adjustment work 4‐3 1 Aligning the focusing optics 4‐4 1.1 Aligning the focusing optics 4‐4 2 Adjusting the focal position 4‐6 2.1 Setting zero position 4‐7 2.2 Taking objects out of the beam guideway 4‐8 2.3 Adjusting the working distance 4‐8 Determining the focal position with the working laser 4‐10 Measuring the working distance 4‐11 Adjusting the focal position by means of the line laser 4‐13 2.
2.7 4‐2 Adjustment work Adjusting the focusing optics in the x-y direction. 4‐19 Adjusting the focusing optics, zero position 4‐20 Adjusting the focusing optics to a new workpiece 4‐20 3 Adjusting the dual focus optics 4‐21 3.1 Turning the focal points around the center axis 4‐21 3.2 Adjusting the splitting ratio 4‐22 4 Adjusting the Gen 2 observation optics 4‐24 4.1 Adjusting the picture sharpness of the camera 4‐24 4.2 Adjusting the cross hairs 4‐25 4.
General notes on adjustment work The following conditions must be fulfilled: ■ ■ ■ ■ ■ 22-50-17-CRen 2020-01 The focusing optics must have been installed in the system. The focusing optics must have been connected correctly to the laser device by way of the LLK. The necessary safety equipment must have been installed and must be ready for operation. Suitable laser safety glasses must be at hand. There must be enough samples for the commissioning procedure.
1. Aligning the focusing optics In almost all applications the optical axis of the focusing optics is aligned with the processing plane. 1 3 1 Guide edge on the connecting piece 3 2 Guide edge on the lens protection CT-00481 2 Workpiece Aligning the 0° focusing optics with the processing plane Fig. 4-1 The 0° and 90° focusing optics have to be aligned in the same way. 1.
or Ø Align the guide edge of the lens protection (2) in parallel to the workpiece (3) (see "Fig. 4-1", pg. 4‐4). Tip If welding is performed with strong back reflections, the focusing optics should be set at an angle so that the back reflections pass by the focusing optics. An external absorber plate may also be required.
2. Adjusting the focal position The highest power density of the laser beam is achieved in the focal point. The position and the diameter of the focal point as well as the depth of focus depend on: ■ ■ ■ the focal length of the used lens. the core diameter LLC. the focal length of collimation. The deviation of the focal position Δz from the workpiece surface has an important effect on the geometry of the weld point or welding seam.
2.1 Setting zero position Please see the following sections: ■ ■ ■ ■ Taking objects out of the beam guideway. Adjusting the working distance. Defocusing the focusing optics. Adjusting the focusing optics in the x-y direction.. With zero position and distance B between the focusing optics and the workpiece adjusted according to the dimensional drawings, the focal plane lies exactly on the workpiece surface.
2.2 Taking objects out of the beam guideway The laser beam exits the lens conically and achieves its highest power density in the focal point. Objects in the beam path cause ■ ■ ■ ■ increased scattered light at the machining point. risk of overheating of the object projecting into the beam path. backscattering of the laser light into the focusing optics. This causes additional heating-up of the focusing optics and may result in damage to the focusing optics and the laser device.
The focal position must be determined anew if: ■ ■ the focusing optics has been replaced. the clearance between the lens and workpiece has changed. Method Explanations with camera The working distance is changed until the workpiece surface is sharply defined. Note This method is only possible if the camera is adjusted correctly. according to dimensional drawing of the focusing optics Adjust the working distance according to distance B (see dimensional drawing of the optics used).
Determining the focal position with the working laser Conditions The focusing optics is connected to a laser device. The laser device has been turned on. ■ ■ WARNING If the laser beam exit and the processing point are not placed in a protective cover, your eyes and your skin may be exposed to laser light! Laser light can burn your skin or irreparably damage your eyes. Ø Ø Do not put your hands between focusing optics and workpiece while laser light is emitted.
B 1 1 0030-23-T 2 1 Anodized aluminum sheet 2 Smallest weld point B Space from lower edge of lens protection to focal plane Determining the focal position with the working laser Fig. 4-5 2. Put an anodized aluminum sheet (1) on the working table. 3. Adjust distance B according to the dimensional drawing. 4. Apply several weld points on the anodized aluminum sheet. There should be a space of approx. 6 mm between the weld points.
Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock. or ■ The light path to the focusing optics is blocked. Note Do not use pointed measuring instruments for measurements on the protective glass to avoid scratches.
Adjusting the focal position by means of the line laser Condition ■ The line laser has been adjusted correctly (see "Adjusting the line laser", pg. 4‐14). 3 1 0040-73-T 2 1 Line of the line laser (focal 3 plane not on the workpiece surface) 2 Workpiece Line of the line laser is located on the point of the pilot laser Light of the pilot laser and the line laser Fig. 4-7 Your eyes may be exposed to the laser light of the pilot laser.
Caliper L69-235 3 4 2 0031-55-T 1 1 Tip 1 (69 – 128 mm) 3 Sleeve 2 Locking screw (3 x) 4 Tip 2 (178 – 235 mm) Fig. 4-8 1. 2. 3. 4. Loosen the clamping screws (2). If necessary, shorten the tip 2 (4) to the desired length. Insert the appropriate tip 1 or 2 (1 or 4) into the sleeve (3). Position the caliper between the focusing optics and workpiece at an easily accessible point where the working distance can be adjusted or checked. 5.
Switch on line laser Your eyes may be exposed to the laser light of the pilot laser. WARNING The laser light of the pilot laser can irreparably damage your eyes. Ø Wear adjustment goggles that will protect the laser light wavelength of 635 nm used. 1. Switch on the pilot laser of the shutter switch. 1 Clamping screw 4 Line laser 2 Laser module 5 3 Clamping holder, line laser Adjusting screw (linear adjustment) 6 Knurl for axial adjustment Line laser and removed laser module Fig. 4-9 2.
11. Tighten the clamping screw again. 12. Switch off the line laser. This completes the adjustment of the line laser. 3 1 0040-73-T 2 1 Line of the line laser (focal 3 plane not on the workpiece surface) 2 Workpiece Line of the line laser is located on the point of the pilot laser Light of the pilot laser and the line laser Fig. 4-10 Tip The easiest way of line laser adjustment is when using a camera for viewing.
CT-00484 Scales Scale on the collimation unit Fig. 4-11 The focus length set can be read off the scales on top of and below the setting ring. The shift in focal position Δz can be read in mm on the scale (arrow). Once the focal length of the lens is known, you can determine approximate displacement of the focal position Δz as follows: SG-02005 Focal lengths of lens Fig.
or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ Allen key, 90°, AF2 Tool for adjusting the collimation: arbor or pin with diameter 2.1 mm, alternatively hexagonal socket screwdriver AF2 3 Adjusting ring in zero position ■ 1 Screws 2 Cover sheet 4 Adjusting ring in defocused position Fig. 4-13 1. Undo the screws (1) and dismantle the covers (2) on both sides. 2.
2.7 Adjusting the focusing optics in the x-y direction. The x-y direction of the laser beam in the focusing optics is set by TRUMPF on delivery as specified in the dimensional drawing. Note After installation of the focusing optics in a system environment, the zero point for the x-y direction has to be determined. Focusing optics, x-y direction 22-50-17-CRen 2020-01 Fig.
WARNING If the laser beam exit and the processing point are not placed in a protective cover, your eyes and your skin may be exposed to laser light! Laser light can burn your skin or irreparably damage your eyes. Ø Ø Do not put your hands between focusing optics and workpiece while laser light is emitted. Wear laser glasses suitable for the wavelength of the laser light.
3. Adjusting the dual focus optics 3.1 Turning the focal points around the center axis Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock. or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ Internal hexagon screwdriver, X20 Allen key, 2 mm Arbor, 2.
3.2 Adjusting the splitting ratio Means, Tools, Materials ■ Allen key, 2°mm Note The bifocal optics is preset and does not normally need to be adjusted. Adjusting part ratio Y 1 Set screws 2 Adjusting screw 3 Adjusting screw Fig. 4-16 1. Using a welding test, check whether: − the position of the focal points with respect to the middle axis is correct. − the two weld points or seams have the same size and depth. 2. Remove the cover and seal. 3.
The position of the focal points with respect to the centre axis is not correct or the two weld points or weld seams are not equally large or deep. Ø Repeat the setting procedures.
4. Adjusting the Gen 2 observation optics The operations which can be carried out at Gen 2 observation optics are described in this section. You will learn how to: ■ ■ ■ adjust the picture sharpness or the camera. adjust the cross-hairs. adjust the fiber end of the pyrometer. 4.1 Adjusting the picture sharpness of the camera The picture sharpness of the camera has been adjusted ex works. Carry out the following steps to improve the picture sharpness, if necessary.
Adjusting the picture sharpness 1 2 3 CT-00486 4 1 camera 3 Adjustment screw (2x) 2 Safety screw 4 Allen screws (2x) Fastening the camera Fig. 4-17 2. Undo the two Allen screws (4) and remove the cover plate. 3. Turn the setting ring below by hand or with a hexagonal socket screwdriver ≤ AF2. 4. watch the monitor with the camera picture 5. If the image of the processing point is sharp, reinstall the cover and tighten the screws. 4.
1 camera 3 Adjustment screw (2x) 2 Safety screw 4 Allen screws (4x) Adjusting the cross-hairs Fig. 4-18 1. Undo the Allen screws (4) slightly. 2. Use the adjusting screws (3) to make adjustments in the X and Y direction. 3. Tighten the Allen screws (4). The cross hairs are fixed in the center of the picture. Tip The crosshairs can also be moved digitally via the panel PC, see "VisionLine" Operator's manual, doc. no.: 22-50-12-A0-CR. 4.
Adjusting the pyrometer spot in x-y direction 1 Pyrometer outlet 2 Deflection Pyrometer outlet Fig. 4-19 1. To adjust the pyrometer spot in x-y direction, proceed as when adjusting the crosshairs (see "Adjusting the cross hairs", pg. 4‐25). Optimizing the signal strength of the thermal radiation 2. To optimize the signal strength of the thermal radiation, which is coupled into the pyrometer fiber, it may be necessary to adjust the intermediate layer of the coupling lens.
4‐28 Adjusting the Gen 2 observation optics 2020-01 22-50-17-CRen
Chapter 5 Maintenance 22-50-17-CRen 2020-01 1 General notes 5‐3 2 Material 5‐5 2.1 Wearing parts 5‐5 2.2 Optics cleaning kit 5‐5 2.3 Consumables 5‐6 2.4 Disposal 5‐6 2.5 Tools and additional equipment 5‐7 3 Laser light cable (LLK) 5‐9 3.1 Disconnecting the LLK from the focusing optics 5‐9 4 Welding optics 5‐12 4.1 Cleaning the protective glass in the lens protection (process protective glass) 5‐13 4.
4.3 Replacing the protective glass of the lens protection (additional protective glass) 5‐15 4.4 Cleaning the protective glass in the process protective glass cassette 5‐18 4.5 Changing the protective class of the process protective glass cassette 5‐19 4.6 Changing the protective glass of the objective protective glass cassette 5‐23 4.7 Cleaning the splash guard 5‐27 4.8 Mounting the crossjet in a different position 5‐27 4.9 Cleaning the attachment parts 5‐29 4.
1. General notes The correct maintenance is an important precondition for troublefree operation of the focusing optics and for the quality of the working result. The focusing optics has been designed to require little maintenance. Regularly check the condition of your focusing optics. Carry out maintenance work as a precautionary measure when you detect signs of wear or dirt. Check regularly the laser light cable for damaged sheathing. The laser light cable must be replaced in case of a damaged sheathing.
Maintenance of the focusing optics When processing material with a laser, particles or vapors may be emitted from the surfaces of the workpieces, which will result in a fog and a soiling on the protective glass or on other parts of the focusing optics. A soiled protective glass diminishes the laser power on the workpiece. Regularly check the condition of the protective glass. Clean the protective glass and other parts of the focusing optics if they are visibly soiled.
2. Material 2.1 Wearing parts Designation Material No. Lens protection Protective glass D39x1.5 S09 T950 Q 2294542 Protective glass cassette Basic Protective glass D39x1.5 S09 T950 Q 2294542 Process protective glass cassette T950 D50 2356839 Objective protective glass cassette T950 D50 2356874 Flap with grooved ring 2337347 Protective glass D39x1.
2.3 Consumables For maintenance work on the focusing optics, you need the following consumables: Lens cleaning paper or swabs to clean optical glasses (available from the photo shops). Methanol as cleaning agent for optical glasses. Isopropyl alcohol as a cleaning agent for plastic e.g. sealing rings. ■ ■ ■ CAUTION Methanol is inflammable and toxic when you inhale or swallow it. Ø Ø Ø Ø Keep methanol away from open fire and other ignition sources. Do not smoke. Supply sufficient fresh air.
2.5 Symbol Tools and additional equipment Designation Dimensions, other data Slotted screwdriver 5 mm Allen key, straight 2 x 1.5 mm for cutting optics, 4 mm Allen key, 90° AF2, AF2.5, AF3 Open-end wrench 5.
Designation Dimensions, other data Optics cleaning kit(see "Optics cleaning kit", pg. 5‐5) contains tools and consumables for maintenance work on the focusing optics Key for optics welding optics accessory required for replacement of the protective glass TE-01607 Symbol Tools and auxiliary tools for maintenance 5‐8 Material Tab.
3. Laser light cable (LLK) 3.1 Disconnecting the LLK from the focusing optics If you need to separate the LLK from the focusing optics, the same rules as for connecting apply: Avoid anything that poses a risk of soiling. Conditions ■ ■ ■ The focusing optics is mounted to the carrier. The LLK is still connected. The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock.
2. 1. CT-00425 3. Dismounting the LLK plug Fig. 5-2 3. Loosen the adhesive tape from the joint (1). 4. Push sliding sleeve (2) towards the focusing optics until this engages. 5. Unplug the LLK plug from the plug receptacle of the focusing optics (3). Fig. 5-3 Mounting the sealing plug 6. Immediately plug the sealing plug into the plug receptacle (1) and put the protective cap on the LLK plug. 7. Turn the sliding sleeve 5° to the right until this locks.
Fig. 5-4 8. If possible, adhere seal band to the beginning of the adhesive tape on focusing optics and LLK plug. The focusing optics can now be handled separately from the LLK.
4. Welding optics The lens is covered on the outside by a protective glass. The protective glass protects the lens against soiling by particles or material vapors formed during the welding process. Clean the protective glass if: ■ ■ the welding results are affected negatively. the protective glass is dirty. The process protective glass must be replaced if: ■ ■ dirt particles cannot be removed by cleaning (e.g. burnt-in particles). there are scratches on the protective glass.
4.1 Cleaning the protective glass in the lens protection (process protective glass) Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock. or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ ■ ■ Lens cleaning paper or swab Methanol Disposable gloves Note Touch neither the protective glass nor the focusing lens with the fingers. For cleaning, use methyl alcohol.
4.2 Changing the protective glass of the lens protection (process protective glass) Material numbers can be found in the consumable table (see "Wearing parts", pg. 5‐5). Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle type connector. or ■ The light path to the focusing optics is blocked.
3 Retaining ring 6 protective glass holder 4 Protective glass 7 O-ring 5 O-ring Lens protection, components Removing the protective glass Inserting a new protective glass Fig. 5-6 1. Screw off the lens protection (2) from the lens (2) counterclockwise. 2. Cover the opening of the focusing optics in loaded environments (e.g. in case of oil mist or intense dust), until you reattach the lens protection. 3. Unscrew the retaining ring (3) using the optics key. 4.
Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle type connector. or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ ■ ■ ■ Key for optics New protective glass New O-ring (if required) Disposable gloves Note Touch neither the protective glass nor the focusing lens with the fingers.
3 Key for optics 4 Holder ring Removing the protective glass Fig. 5-8 2. Screw the retaining ring (4) with the key for optics (3) out of the lens protection receptacle. Note When replacing the protective glass, make sure that no dirt particles fall onto the focusing lens. 3. Cover the opening of the focusing optics in loaded environments (e.g. in case of oil mist or intense dust), until you reattach the lens protection. 4. Remove the O-ring and protective glass from the retaining ring. 5.
4.4 Cleaning the protective glass in the process protective glass cassette Conditions ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle type connector. or ■ ■ ■ The light path to the focusing optics is blocked. The objective protective glass cassette is inserted. All gases (crossjet, MDE nozzle and purging gas) are turned off.
Fig. 5-10 2. Cover the opening of the protective glass cassette in contaminated environment (e.g. in case of oil mist or a very dusty environment), until you reinsert the protective glass cassette. 3. Soak the lens cleaning paper or a swab with methyl alcohol. 4. Slowly wipe across the protective glass until it is clean. 5. Push the protective glass cassette into the cassette receptacle until the slide engages audibly. Note Only one side of the protective glass may be used.
or ■ ■ ■ The light path to the focusing optics is blocked. The objective protective glass cassette is inserted. All gases (crossjet, MDE nozzle and purging gas) are turned off. Means, Tools, Materials ■ New protective glass for process protective glass cassette New flap with grooved ring (if required) Lens cleaning paper or swab Methanol 3 Cartridge holder ■ ■ ■ Removing the protective glass 1 Process protective glass cassette 2 Slide 4 Protective glass Fig. 5-11 1.
Inserting new protective glass (BEO D50 Basic) 1 Flap with grooved ring 2 Tab for opening the flap 3 Protective glass 4 Flap with grooved ring (open) Fig. 5-12 3. When the protective glass cassette is removed, move the tab (2) up with your index finger and open the flap. 4. Take the protective glass (3) out of the protective glass cassette. 5. Soak lens cleaning paper or swab with methyl alcohol and clean the protective glass cassette. 6. Clean the flap and grooved ring with methanol.
Ø Changing the objective protective glass (see "Changing the protective glass of the objective protective glass cassette", pg. 5‐23). 10. Push the protective glass cassette into the cassette receptacle until the slide engages audibly.
Fig. 5-15 15. Insert a new protective glass into the protective glass cassette. 16. Make sure that the insertion aid with RFID chip (5) is lying correctly in the provided recess at the corner of the cassette. 17. Close the flap. 18. Change the objective protective glass. If soiled: Ø Changing the objective protective glass (see "Changing the protective glass of the objective protective glass cassette", pg. 5‐23). 19.
Removing the objective protective glass cassette 1 Process protective glass cas- 3 sette 2 Objective protective glass cassette Fixing screws Objective protective glass cassette, BEO D50 Basic (left) and BEO D50 Smart (right) Fig. 5-16 1. Undo the fixing screws (3) and pull out the objective protective glass cassette (2). 2. Cover the opening of the protective glass cassette in contaminated environment (e.g.
5. Soak lens cleaning paper or swab with methyl alcohol and clean the objective protective glass cassette. 6. Clean the flap and grooved ring with methanol. If the grooved ring is damaged: Ø Replace flap with grooved ring. Ø To do this, loosen the fastening screws to the left and right on the flap. Note Do not touch the protective glass cassette with the fingers. Fig. 5-18 7. Insert a new protective glass into the protective glass cassette. 8. Close the flap. 9.
10. When the objective glass cassette is removed, move the tab (2) up with your index finger and open the flap. 11. Remove the protective glass from the objective protective glass cassette. Tip The protective glass can be held using the insertion aid with RFID chip (5). 12. Soak lens cleaning paper or swab with methyl alcohol and clean the objective protective glass cassette. 13. Clean the flap and grooved ring with methanol. If the grooved ring is damaged: Ø Replace flap with grooved ring.
4.7 Cleaning the splash guard The crossjet is sealed from below by means of a spatter guard or the MDE nozzle body. Material spatter from the melt are deposited onto these components during the welding process. Clean the spatter guard at regular intervals. The cleaning interval depends on the application and the resultant soiling. Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock.
or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ CAUTION Allen key, 2.5 mm Hot surfaces on the crossjet can burn your skin! If the crossjet is installed incorrectly, the laser beam will hit the crossjet and can heat this up until it glows. Ø Ø Avoid contact with hot surfaces. Check whether the crossjet is correctly installed. Disconnecting supply air hose from the crossjet 1 Fastening screw crossjet (6 x) 2 Hexagon nut Fig. 5-21 1. Release hexagonal nut (2). 2.
4.9 Cleaning the attachment parts During the welding process, material spatter from the melt will be deposited on attachment parts e.g. the shielding gas supply line. The attachment parts should be cleaned regularly. The cleaning interval depends on the application and the resultant soiling. See the Spare parts catalogue for the material numbers. Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock.
or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ Allen wrench, 2 mm 1. 2. 3. 4. Disconnect the plug of the connecting cable from the PLC. Loosen the two fastening screws of the sensor module. Clean the screw-down surface. Then, directly install the new sensor module in the reverse order. 4.11 Replacing the protective glass monitoring module The protective glass monitoring module is for monitoring the cassettes and any contamination of the protective glass.
Fig. 5-22 1. Disconnect the plug of the connecting cable from the interface module or the connecting cable to the laser device. 2. Loosen the two fastening screws of the protective glass monitoring module. 3. Clean the screw-down surface. 4. Then directly install the new protective glass monitoring module in reverse order. Make sure that the antennas and scattered light diodes which project from the protective glass monitoring module are free of contamination.
Condition ■ The connected laser device has been switched off and secured against renewed switching on, e.g. by means of a shackle padlock. or ■ The light path to the focusing optics is blocked. Means, Tools, Materials ■ ■ ■ Protective gloves Collecting tank Slotted screwdriver, 3 mm Removing the focusing optics 1. Unscrew focusing optics from the holder or the customer-provided mounting plate. 2. Disconnect focusing optics from the electrical system and the supply media.
Chapter 6 Eliminating faults 22-50-17-CRen 2020-01 1 Conduct in case of malfunctions 6‐2 1.1 Step-by-step procedure: 6‐2 1.2 Troubleshooting 6‐2 1.3 Observing messages 6‐3 1.
1. Conduct in case of malfunctions During daily work, malfunctions may occur which have to be rectified before the regular operation can be started again. 1.1 Step-by-step procedure: 1. Identify the cause of the fault. 2. Take the recommended measures. DANGER Actions carried out in order to rectify causes of malfunctions might involve risks to you, to other persons or to material property. If such risks are not avoided, they can lead to death, serious injuries or considerable damage to property.
− − − − 1.3 Is it a malfunction of the laser device or of the laser light cable? In this case, a message is displayed on the screen, containing information on the location of the malfunction and the steps for eliminating the causes. Information on how to deal with the messages can be found in the operating software manual and in the Operator's manual for your laser device. Was the malfunction caused by an external component? Example: "EMERGENCY STOP circuit is not closed.
For further information on messages and the necessary actions, please refer to the software manual of the controlled focusing optics. 1.4 Malfunctions, possible causes and measures Welding result went off ■ ■ ■ ■ ■ ■ 6‐4 Protective glass dirty − Clean the process or objective protective glass or replace it if required (see "Cleaning the protective glass in the process protective glass cassette", pg. 5‐18) To identify dirt on the protective glass, e.g.
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ 22-50-17-CRen 2020-01 Position of optics changed (collision, vibration, insufficient fastening) − Readjust the optics to workpiece (see "Adjusting the focal position", pg.
Welding seam not smooth ■ Effects of shielding gas insufficient − Check shielding gas supply: Level of gas bottle; replace empty gas bottle if necessary − Check hoses; they must not be kinked or crushed − Check flow; check nozzles for contamination; clean or replace, if necessary − Check gas quality and type ■ Insufficient cooling water flow or no cooling water flow at all − Checking the flow − Check hoses; they must not be kinked or crushed Protective glass dirty − Clean the process or objective protect
■ ■ Dirt on optical components (collimation, mirror, lens) − Visual inspection of the optics: Loosen and remove the LLK plug Hold the optics against a light source and inspect its condition via the plug receptacle − Replace the optical component if soiled, Call the TRUMPF customer service Higher load on optics than permissible ex works − Call the TRUMPF customer service Incorrect welding position ■ ■ Monitoring by means of the camera unsatisfactory ■ ■ Protective glass monitoring unit logs itself on
2. Informing the service department If a fault occurs and you need assistance in eliminating it, please contact the TRUMPF service department. The service address is to be found at the beginning of these operating instructions, following the front page. Please tell the service staff as precisely as possible: ■ ■ ■ ■ What happened? What has been displayed on the screen (e.g.
