大功率橫流co激光器升級改造項目

1、Power Cross-Flow CQ大功率橫流CQ激光器升級改造項目2 Laser Up grading P rojects1.項目概要通過對國內(nèi)大功率橫流 CO2激光器使用單位的調(diào)查和技術(shù)分析，結(jié)合我公司在橫流CO2激光器方面的技術(shù)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(shè)備的使用單位進行充分的技術(shù)交流，通過技術(shù)服務(wù)，對激光設(shè)備的關(guān)鍵部位進行技術(shù)改造。一方面，可大幅提升激光器的輸出功率（-2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(wù)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CO激光器的加工潛力，幫助國內(nèi)各激光加工單位拓展激光加工領(lǐng)域，如

2、激光焊接。1. In troduct ionThrough the cross-flow of domestic high-power CO2laser units use the investigationand technicalan alysis, the comb ined company in the cross-flow CO2 laser's tech ni cal sup eriority, I decided to con duct some on-l ine laser up grad ing p rojects.With the hope that the use

3、 of laser equ ipment un its sufficie nt tech ni cal excha nges, tech ni cal services, the key parts of laserequ ipment for tech no logical tran sformati on.dramatically enhance the laser out put po wer to 2 times) and op erat ing stability, enhance conven ti onallaser harde ning and laser cladd ing

4、p rocess ing bus in ess pr oductivitycan in crease the out put of low-efficie ncyand give fullp lay to Power cross-flowpoten tial of the domestic help expand the laser pr ocess ing un its laser p rocess ing areas, such as laser weld ing.On the one hand, canon the other hand,CO2laser processing2.市場調(diào)查

5、分析目前，通過對國內(nèi)千瓦級大功率 CO2激光熱處理和激光熔覆設(shè)備的用戶進行調(diào)查,很多用戶反映設(shè)備性能較差，大部分情況為：設(shè)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(shè)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(guān)鍵技術(shù)指標(biāo)達不到標(biāo)準(zhǔn)。2. Survey of the marketAt present, through the domestic kilowatt-class high-power CO2laser heat treatment laser cladding of the user survey, many use

6、rs reflect the poor performanee of equipment, of cases are: stability of poor equ ipment, five times the n umber of failures in more tha n the use of lasers One to two years after the po wer out put smaller model deteriorate,result ingsets of equi pment most ofte n in the low p erforma nee, or eve n

7、 outages. Laser focus on key issues in the key in dicators-sta ndard tech no logy.equipment andthe majorityin complete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 i I IIii在額定功率的60%F運行（如5000W橫流CO2激光器可9I以穩(wěn)定運行的功率僅為3000vy，也有顯示的功率數(shù)偏高Ii激光功率“大打iiii的現(xiàn)象；如5000W橫流CO2激光器功率計顯示輸出功率iI折扣”，影響加工jI!為5000W按計量

8、局標(biāo)準(zhǔn)的手持功率檢測儀器顯示僅為 效率ii 3000W因此，很多高功率設(shè)備處于低功率運行狀態(tài)，加工i效率降約為標(biāo)準(zhǔn)的一半。I1根據(jù)行業(yè)技術(shù)標(biāo)準(zhǔn)的規(guī)范，合格的橫流 CO2激光器IIi可以獲得多模和低階模兩種激光束模式，低階模狀態(tài)的II3Ii功率為多模的1/2。i丨目前國內(nèi)的大部分橫流CO2激光器通過加“光柵” ii低階模狀態(tài)性能j!取得低階模狀態(tài)，只能獲得多模功率的 1/3左右；按照差，無法開展新丨Iii上面多模激光輸出功率情況，以 5000W的橫流CO2激光ii業(yè)務(wù)（激光焊接、！I$器為例，在低階模穩(wěn)定運行狀態(tài)下，只獲得 1000W左右汀激光切割）iiii （按技術(shù)標(biāo)準(zhǔn)可獲得低階模25000。

9、iI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IIi應(yīng)用技術(shù)。I設(shè)備運行過程中，經(jīng)常出現(xiàn)光路偏差、電路故障等i問題，影響生產(chǎn)進度。3 i激光器穩(wěn)定性差i經(jīng)過調(diào)查分析，激光器的諧振腔穩(wěn)定性差，容易出 i現(xiàn)光軸漂移，引起光斑能量分布不均和激光束偏離外光3I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。j對于復(fù)雜的熔覆工藝，大部分激光設(shè)備客戶采用重4丨工藝裝備差=力送粉機構(gòu)，進行鋪粉或預(yù)置粉末的辦法；無法對復(fù)雜a!形狀的零部件進行三維送粉和修復(fù)。1kw-class high-po wer C02 laser and the

10、main p roblems describedNo.Main issuesBriefi Lasers can not be rated power under the stable operation of!ai:power only in the highest rated power of running under 60:!Laser po wer "greatlyJ reduced", the:percent (5000 Wcross-flow CO2laser can only stable operation ! of power 3000 W), also

11、shows that the number of high-poweri I:phenomenon such as the 5000 Wcross-flow CO2laser power meter 'imp act onI processing! efficiency:!i showed that out put of 5000 W, measured by the sta ndard|:!5 hand-held power detection equipment showed that only 3000 W. i :!:Therefore,many high-power equi

12、pment in a low-power! i operation, and processing efficiency drop of about half the!Iji standard.5 -4:Accordingto industry technical standard specifications,i qualifiedcross-flow CO2laser can be multi-mode and low-end i .1:two-modelaser beam, low-power status for the multi-mode 15h 2.Ii Poor perform

13、aneeof low-status, un able to carryi2 I out newop erati ons (laser weldi ng, laser=cutt ing)i Most of the:in creases,i be 1 / 3 ofcurrent domestic CO2laser through the cross-flow "grating" a low-status, multi-mode power can only around accordanee with the above multi-modelaseriIj Laser poo

14、r3 stability:Poor technical4 Ji equipmenti out put po wer, to 5000 W of the cross-flow CO2 laser as an:example, in Low-end module and stable operation of state,i received only about 1000 W (at the technical standards=available to low-e nd module 2500 W).:Therefore, most have been put into production

15、 in theiI cross-flow CO2 laser beam only a multi-mode, almost no:development of low-end module and the ring-laser weldingI applications.i In the course of operation of equipment, often light pathi：deviation circuit fault and other issues affecting thei progress of production.ii After an investigatio

16、n of the laser resonator stability of:poor, vulnerable tothe optical axis drift, caused spots andii uneven distribution of energy laser beam from the opticalcen ter; po wer use circuit board con trol, stability poor:discharge system to produce a small gain.1T T T T T T 1:The compl exity of the cladd

17、 ing tech no logy, laser equi pment,i most of the feeding by gravity, a shop powder or preferencesi powder; unable to complex 3-D shape of the feeding parts andI rep air.3.項目實施內(nèi)容升級部位升級項目技術(shù)及功能特點描述序I升級部位丨升級項目號丨丨技術(shù)及功能特點描述2 Technical and functional characteristics described、/、FT、/' 光器光腔激光器電源、電氣控制部分i

18、光腔采用1I “高可靠模:I塊化”結(jié)構(gòu)i光腔采用1I “二折高效:j復(fù)合腔”機1光腔模塊結(jié)構(gòu)包括：位置調(diào)整模塊、角度調(diào)整模塊、前腔模塊、后腔模塊、光軸監(jiān)測模塊。光腔調(diào)整簡單、可操作性強；降低光腔維護成本。M MM MM M I該復(fù)合腔在不改變原光腔長度的前提下，增加腔內(nèi)諧振范圍，放電增益區(qū)進行充分的激光振蕩，電光轉(zhuǎn)換效率達到18%上。二折腔機構(gòu)相當(dāng)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-$放電極采用4:1多排針放電I結(jié)構(gòu)4dhhd亠hd 1 dhdhhi風(fēng)機電機驅(qū)3動變頻控制增加倍。采用工控機作為激光器控制中心，對電流、氣壓、水流均采用高可靠性傳感器件，將采集到i的

19、信號輸入到工控機中，經(jīng)程序運算后，輸出到相應(yīng)控制繼電器或輸出相應(yīng)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I控制系統(tǒng)具有高的穩(wěn)定性及可靠性。 r B-r T r ¥T ¥T ¥B-r ¥r-r 1采用多排放電針放電結(jié)構(gòu)，可以實現(xiàn)3排針i或更多排放電結(jié)構(gòu)，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。IIk 亠 h 11 d ah 11 d 亠 d h h m d 亠 d h h m d 亠 d h a h m 1 4I 風(fēng)機電機驅(qū)動采用變頻控制器，通過改變頻I I率來獲得不同的電機轉(zhuǎn)速，實現(xiàn)風(fēng)機由慢到快的平穩(wěn)提速過程，同

20、時可以通過工控機實現(xiàn)風(fēng)機轉(zhuǎn)速的優(yōu)化調(diào)整。適當(dāng)?shù)奶岣哳l率，可增大風(fēng)機的轉(zhuǎn)速，獲得更高的激光輸出功率。j Up grade3i projects3. Contents Of P roject ImpI eme ntati oni Up grad ing No. 3site:Up grad ingNo. 3 sitei Up grade projects:Technical and functional characteristics described:Cavity of "highlyi reliablei modular"3 structureLaser cavityj C

21、avity of " j presentation I of comp lexi cavity efficient" body5 Cavitymodule structure,including:positioni IiI:adjustmentmodule,angle adjustment module, the'I1 former chamber module, after the chamber module,4j optical axismonitoringmodule.i1 I2 Cavityadjustme ntssimple and easy to op

22、 erate; lower !3II cavity maintenance costs. '- WF WF WF wr wr wri-w :The cavity in the compound does not cha nge the1 Ij length of the cavity under the premise of increased!'The j!i cavity resonance of the district gain full discharge i ii:of laser oscillati on,electro-op tical con vers ion

23、 ；1 Ii efficiency of 18 percent or more.iIiI The pr ese ntati on of chamber body cavity equivale nt| I :to double the length, taking intoaccount the '3 I1 Ij discharge gain Width restrictions, can achieve aniJIj in crease of times the rated po wer.|I IPC used as a laser control centre, the curre

24、nt,! Controli system usesI IPC control.Laser Po wer,卜 1the electric Discharge iscon trol p art:multi-needleofi dischargej structurea:Fan motor3 drive!5 inverter:controli Pressure, flow sensors are used pieces ofiIiJII high-reliability, the signal will be collected intoiIIIthe IPC, the operator proce

25、dures, correspondingto!J4Ijcon trol out put or out put relay corres pondingiIi:simulati on Volume, while the out put sig nal detecti on iI!Ifeedback to ensure a smooth process to ensure thatiJ4I the entire control system with high stability and1Ireliability.!*j A multi-emissionselectric discharge st

26、ructure, can i:achieve three or more emissions-ranked powerI structure, increasing gain zone width; discharge3I needles are each fine-tune treatment, the discharge:system more stable.屮3S44 43i43 3 3I Fans used frequency motor drive controller, byj:changing the frequency of differentmotor speed,!:fan

27、s from slow to fast speed of a smooth process,ij also through the IPC to achieve optimal adjustmenti:of the fan speed. The improvement of appropriateII freque ncy, can in crease the fan sp eed, the higher!i laser po wer out put.and i but 'the !4.項目實施技術(shù)指標(biāo)本升級改造項目的立項宗旨為：技術(shù)指標(biāo)達到國內(nèi)行業(yè)標(biāo)準(zhǔn)，部分技術(shù)指標(biāo)超過行業(yè)標(biāo)準(zhǔn)。（關(guān)

28、于大功率橫流連續(xù)波 CO2激光器的技術(shù)標(biāo)準(zhǔn)，請來電索?。┮試鴥?nèi)現(xiàn)行5KW激光器為例，實施升級改造后的技術(shù)性能指標(biāo):激光器光腔部分:橫模模式TEMmnm+nc 1多模備注I額定輸出激光功率（P） W高于行業(yè)標(biāo):i準(zhǔn)40007500I （行業(yè)標(biāo)準(zhǔn)! 5000W)*間（t）h> i241行業(yè)標(biāo)準(zhǔn):額定輸出激光功率穩(wěn)定度% ! a :± 2i行業(yè)標(biāo)準(zhǔn)光束指向穩(wěn)定度 mradc: 1 行業(yè)標(biāo)準(zhǔn)束散角（全角）mradcI1:ai !1151 H HH H 11行業(yè)標(biāo)準(zhǔn)-H H H H H H H-H H H H I光束傳輸因子（K）>a :111I1I1行業(yè)標(biāo)準(zhǔn)激光器電光轉(zhuǎn)換效率%&

29、gt;5I1:1111i !1i高于行業(yè)標(biāo)1i91!1!1!18i準(zhǔn)（行業(yè)標(biāo)準(zhǔn)I aI1i1i 為 16%激光波長 卩m1a:11:1電源、電氣控制部分CE放電電流不穩(wěn)定度 % 亠 1 亠_亠_亠 亠_亠 _ 1 _電子元器件年故障率次/年h± 2:行業(yè)標(biāo)準(zhǔn)1 _亠- U 亠 -4 U 亠 1亠 U 1-占- U 亠 亠-亠 U (現(xiàn)行業(yè)狀況約為5)高于行業(yè)標(biāo)!準(zhǔn)放電針結(jié)構(gòu)多排針結(jié)構(gòu)，> 31高于行業(yè)標(biāo)1準(zhǔn)電源、電氣控制模式i工控機（現(xiàn)行業(yè)狀況為集成電路控i高于行業(yè)標(biāo)制）i準(zhǔn)4. Project Implementation SpecificationsThe upgradin

30、g projectfor the purpose of the project:technical indicators have reached the domesticin dustry sta ndards, some tech ni cal in dicators more tha n the in dustry sta ndard. (On "cross-flow con ti nuous wave high-po wer CO2 laser," the tech ni cal sta ndards, calls for)up grad ing the tech

31、nical5 KW to the exist ing domestic laser as an exa mple, the impl eme ntati on ofp erforma nee in dicators:Laser cavity:Cross-mode TEM mnm+nc 1!I 備注Rated out put laser power (P) W4000:Cross-mode TEMmn ：!III * i Higher than the!'industry7500! standardi (Multi-industrysta ndards for! the 5000 W),亠 H_Ld_a4LAH_Ld4H_blRated out put laser po wercontinuousoperationtime (t) h