大功率橫流CO2激光器升級改造項目

1、大功率橫流 CO2 激光器升級改造項目Power Cross-Flow CO 2 Laser Upgrading Projects1項目概要通過對國大功率橫流 CO2激光器使用單位的調(diào)查和技術分析，結合我公司在橫流CO2激光器方面的技術優(yōu)勢，我公司決定開展部分在線激光器的升級改造項目。希望與各激光設備的使用單位進行充分的技術交流， 通過技術服務， 對激光設備的關 鍵部位進行技術改造。 一方面， 可大幅提升激光器的輸出功率 ( 1.52 倍) 和運行穩(wěn)定性， 提高常規(guī)激光淬火和激光熔覆加工業(yè)務的生產(chǎn)效率； 另一方面， 可提高低階模的輸出效率， 充分發(fā)揮大功率橫流 CO2 激光器的加工潛力，幫助國

2、各激光加工單位拓展激光加工領域， 如激光焊接。1 IntroductionThrough the cross-flow of domestic high-power CO2 laser units use the investigation and technical analysis, the combined company in the cross-flow CO2 lasers technical superiority, I decided to conduct some on-line laser upgrading projects.With the hope that the

3、use of laser equipment units sufficient technical exchanges,technical services, the key parts of laser equipment for technological transformation.On the one hand, can dramatically enhance the laser output power (1.5 to 2 times) andoperating stability, enhance conventional laser hardening and laser c

4、ladding processingbusiness productivity on the other hand, can increase the output of low-efficiency andgive full play to Power cross-flow CO2 laser processing potential of the domestic helpexpand the laser processing units laser processing areas, such as laser welding.2 市場調(diào)查分析目前， 通過對國千瓦級大功率 CO2激光熱處

5、理和激光熔覆設備的用戶進行調(diào)查，很多用戶反映設備性能較差，大部分情況為：設備穩(wěn)定性很差，年故障次數(shù)5 次以上；激光器使用一至兩年后出現(xiàn)功率輸出變小、 模式變差， 因此造成大部分成套設備經(jīng)常處于低性能 狀態(tài)，甚至停運。主要問題集中在激光器的關鍵技術指標達不到標準。2 Survey of the marketAt present, through the domestic kilowatt-class high-power CO2 laser heat treatmentequipment and laser cladding of the user survey, many users refl

6、ect the poor performanceof equipment, the majority of cases are: stability of poor equipment, five times thenumber of failures in more than the use of lasers One to two years after the power output smaller model deteriorate, resulting in complete sets of equipment most often in the low performance,

7、or even outages. Laser focus on key issues in the key indicators-standard technology.千瓦級大功率 CO2激光器存在的主要問題及描述序號 主要問題 簡單描述激光器無法在額定功率下穩(wěn)定運行， 最高功率只能在額定功率的 60%下運行（如 5000W橫流 CO2激光器可以穩(wěn)定運行的功率 激光功率“大打折僅為 3000W），也有顯示的功率數(shù)偏高的現(xiàn)象； 如 5000W橫流 CO21 扣”，影響加工效率 激光器功率計顯示輸出功率為5000W，按計量局標準的手持功率檢測儀器顯示僅為 3000W。因此， 很多高功率設備處于低

8、功率運行狀態(tài)， 加工效率降約 為標準的一半。根據(jù)行業(yè)技術標準的規(guī)， 合格的橫流 CO2激光器可以獲得多 模和低階模兩種激光束模式，低階模狀態(tài)的功率為多模的 1/2 。 低 階 模 狀 態(tài) 性 能 目前國的大部分橫流 CO2激光器通過加 “光柵”取得低階模 差，無法開展新業(yè)狀態(tài)， 只能獲得多模功率的 1/3 左右；按照上面多模激光輸出功2務（激光焊接、激率情況， 以 5000W的橫流 CO2激光器為例， 在低階模穩(wěn)定運行狀光切割） 態(tài)下，只獲得 1000W左右（按技術標準可獲得低階模2500W）。因此，大部分已投入生產(chǎn)的橫流 CO2激光器的僅采用多模光 束，幾乎沒有開發(fā)低階模及環(huán)形模的激光焊接應

9、用技術。設備運行過程中， 經(jīng)常出現(xiàn)光路偏差、 電路故障等問題， 影 響生產(chǎn)進度。3 激光器穩(wěn)定性差 經(jīng)過調(diào)查分析， 激光器的諧振腔穩(wěn)定性差， 容易出現(xiàn)光軸漂 移，引起光斑能量分布不均和激光束偏離外光路中心； 電源采用 電路板控制，穩(wěn)定性差；放電系統(tǒng)產(chǎn)生的增益區(qū)小。對于復雜的熔覆工藝， 大部分激光設備客戶采用重力送粉機4 工藝裝備差 構，進行鋪粉或預置粉末的辦法； 無法對復雜形狀的零部件進行三維送粉和修復。1kw-class high-power CO2 laser and the main problems described BriefMain issuesNo.Laser power gr

10、eatly reduced, the 1 impact on processing efficiencyLasers can not be rated power under the stable operation of power only in the highest rated power of running under 60 percent (5000 Wc ross-flow CO2l aser can only stable operation of power 3000 W), also shows that the number of high-power phenomen

11、on such as the 5000 Wc ross-flow CO2 laser power meter showed that output of 5000 W, measured by the standard hand-held power detection equipment showed that only 3000 W. Therefore, many high-power equipment in a low-power operation, and processing efficiency drop of about half the standard.Poor per

12、formance of low-status, unable to carry out new2 operations (laser welding, laser cutting)According to industry technical standard specifications, qualified cross-flow CO2 laser can be multi-mode and low-end two-mode laser beam, low-power status for the multi-mode 1 / 2.Most of thecurrent domestic C

13、O2 laser through the cross-flow grating a low-status, multi-mode power can only around accordance with the above multi-mode laserLaser poor3 stabilityPoor technical4 equipmentincreases, be 1 / 3 of output power, to 5000 W of the cross-flow CO2 laser as an example, in Low-end module and stable operat

14、ion of state, received only about 1000 W (at the technical standards available to low-end module 2500 W).Therefore, most have been put into production in the cross-flow CO2 laser beam only a multi-mode, almost no development of low-end module and the ring-laser welding applications.In the course of

15、operation of equipment, often light path deviation circuit fault and other issues affecting the progress of production.After an investigation of the laser resonator stability of poor, vulnerable to the optical axis drift, caused spots and uneven distribution of energy laser beam from the optical cen

16、ter; power use circuit board control, stability poor discharge system to produce a small gain.The complexity of the cladding technology, laser equipment, most of the feeding by gravity, a shop powder or preferences powder; unable to complex 3-D shape of the feeding parts and repair.3項目實施容序號升級部位升級項目技

17、術及功能特點描述光腔采用“高光腔模塊結構包括： 位置調(diào)整模塊、 角度調(diào)整模塊、可靠模塊化”前腔模塊、后腔模塊、光軸監(jiān)測模塊。結構光腔調(diào)整簡單、可操作性強；降低光腔維護成本。激光器光腔該復合腔在不改變原光腔長度的前提下，增加腔諧光腔采用“二振圍，放電增益區(qū)進行充分的激光振蕩，電光轉(zhuǎn)換效率折高效復合 達到 18%以上。激光器電源、4 電氣控制部分腔”機構控制系統(tǒng)采用工控機控制。放電極采用多排針放電結構二折腔機構相當于光腔的長度增加一倍，考慮到放電增益區(qū)寬度限制，一般可實現(xiàn)額定功率增加采用工控機作為激光器控制中心，對電流、氣壓、1.5 倍。水流均采用高可靠性傳感器件， 將采集到的信號輸入到工控機中，

18、 經(jīng)程序運算后， 輸出到相應控制繼電器或輸出相應模擬量， 同時對輸出信號進行反饋檢測保證程序順利進行，保證整個控制系統(tǒng)具有高的穩(wěn)定性及可靠性。采用多排放電針放電結構， 可以實現(xiàn) 3 排針或更多排放電結構， 增大增益區(qū)寬度； 每個放電針均進行微調(diào)處理，使放電系統(tǒng)更穩(wěn)定。風機電機驅(qū)動采用變頻控制器， 通過改變頻率來獲風機電機驅(qū)動得不同的電機轉(zhuǎn)速，實現(xiàn)風機由慢到快的平穩(wěn)提速過變頻控制程，同時可以通過工控機實現(xiàn)風機轉(zhuǎn)速的優(yōu)化調(diào)整。當?shù)奶岣哳l率， 可增大風機的轉(zhuǎn)速， 獲得更高的激光輸 出功率。3 Contents Of Project ImplementationUpgradingUpgradeTech

19、nical and functional characteristics describedNo.siteprojectsNo.UpgradingsiteUpgrade projectsTechnical and functional characteristics described1Cavity of highly reliable modular structureCavity module structure, including: position adjustment module, angle adjustment module, the former chamber modul

20、e, after the chamber module, optical axis monitoring module.Cavity adjustments simple and easy to operate; lower cavity maintenance costs.2Laser cavityCavity of The presentation of complex cavity efficient bodyThe cavity in the compound does not change the length of the cavity under the premise of i

21、ncreased cavity resonance of the district gain full discharge of laser oscillation, electro-optical conversion efficiency of 18 percent or more.The presentation of chamber body cavity equivalent to double the length, taking into account the discharge gain Width restrictions, can achieve an increase

22、of 1.5 times the rated power.3Laser Power, the electric control part ofControl system uses IPC control.IPC used as a laser control centre, the current, pressure, flow sensors are used pieces of high-reliability, the signal will be collected into the IPC, the operator procedures, corresponding to con

23、trol output or output relay corresponding simulation Volume, while the output signal detection feedback to ensure a smooth process to ensure that the entire control system with high stability and reliability.4Discharge is a multi-needle discharge structureA multi-emissions electric discharge structu

24、re, can achieve three or more emissions-ranked power structure, increasing gain zone width; discharge needles are each fine-tune treatment, the discharge system more stable.5Fan motor drive inverter controlFans used frequency motor drive controller, by changing the frequency of different motor speed

25、, and fans from slow to fast speed of a smooth process, but also through the IPC to achieve optimal adjustment of the fan speed. The improvement of appropriate frequency, can increase the fan speed, the higher the laser power output.4 項目實施技術指標本升級改造項目的立項宗旨為：技術指標達到國行業(yè)標準，部分技術指標超過行業(yè)標準。（關于大功率橫流連續(xù)波 CO2激光器

26、的技術標準，請來電索取）以國現(xiàn)行 5KW激光器為例，實施升級改造后的技術性能指標：激光器光腔部分：備注橫模模式 TEMmnm+n 1多模額定輸出激光功率（ P） W40007500高于行業(yè)標準（行業(yè)標準 多 模為 5000W）額定輸出激光功率連續(xù)運行時間 （t ）h24行業(yè)標準額定輸出激光功率穩(wěn)定度 %2行業(yè)標準光束指向穩(wěn)定度 mrad 0.15行業(yè)標準束散角（全角） mrad 2.05行業(yè)標準光束傳輸因子（ K）0.350.07行業(yè)標準激光器電光轉(zhuǎn)換效率 % 918高于行業(yè)標 準（行業(yè)標準 為16%）激光波長 m10.6電源、電氣控制部分放電電流不穩(wěn)定度 %2行業(yè)標準電子元器件年故障率次/

27、年0.5 （現(xiàn)行業(yè)狀況約為 5）高于行業(yè)標準放電針結構多排針結構， 3高于行業(yè)標準電源、電氣控制模式工控機（現(xiàn)行業(yè)狀況為集成電路控制）高于行業(yè)標準4 Project Implementation SpecificationsThe upgrading project for the purpose of the project: technical indicators have reached the domestic industry standards, some technical indicators more than the industrystandard. (On cross-flow continuous wave high-power CO2l aser, the technical standards, calls for)5 KW to the existing domestic laser as an example, the implementation ofupgrading thetechnical performance indicators:Laser cavity:備注Cross-mode TEMmnm+n1Cross-mode TEMmnRated output la