Treinamento Fibra

Service Training LF100+LF200

ALLTEC Laser Business Unit – 10.04.2008 Page 1

Competence in Laser Marking

Training for operation Maintenance and Serviceof ALLPRINT CO 2-Laser Systems

for the Laser Serie

LF100 / LF200VJ7210 / VJ7310




Introduction Fibre-Laser System



Paint Removal- Paper- Glass etc.

Material Removal (Engraving)- Metal- Glass etc.- Plastics

With low laser intensity, a pure warming-up of the marking zone occurs, e.g.thermal cracking of pigments in a plasticwith subsequent local colour change.

Increasing the laser intensity causes local evaporation of the surface materialwith trench formation. The material is engraved.

Colour Change- Plastics

Surface material removal and reveal of a different-coloured base material.

Material Effects



Markings ILabels/paper

Effect:Paint removalCO2-Laser



Markings IIElectronic components

Effect:Colour changeCO2-LaserNd:YAG-LaserFibre Laser



Markings IIIElectronic components

Effect:Colour changeCO2-LaserNd:YAG-LaserFibre Laser



Effect:Material removal in glass (engraving)CO2-Laser

Markings IVGlass



Effect:Material removal in metal (engraving)Nd:YAG-Laser

Markings VMetal



1. Monochromaticity- The laser emits radiation with only one fixed wave length.

2. Coherence- All amplitudes are running in phase.

3. Directionality- All amplitudes are not divergent, they are nearly parallel.

Because of this they can be well focussed.

ComparisonWhite Light - Laser Light



Effect of the Laser Radiation on the Eye

Laser radiation in the invisible spectrum (e.g. CO 2 laser)

Laser radiation in the visible spectrum, e.g. HeNe- laser (650nm)or near the visible spectrum, e.g. fibre laser (107 0nm) and Nd:YAG-laser (1064nm)

cornea retina

optic nerve

“blind spot“

conjunctiva

lens

laser beam



Where are the dangers of the ALLPRINTCO2 Laser Marking System?

• Invisible laser beam

• Focused laser beam with very high energy densities

• Poisonous gas and dust particles are produced durin g

the marking process

• Reflections (at opened beam delivery system)

• Danger of fire- and explosion

Laser Safety I



The laser beam might cause severe burns of the eyes and the skinas well as damages to

objects!

That means in the worst case:Loss of the eyesight!

Laser Safety II



Never forget when working at the open laser and/or the open beam delivery system:Wear appropriate laser safety goggles!

Indication of suitable laser safety goggles:

Laser Safety III

DI 1050-1400 L7 LV DIN CE DIN CE Check Character Manufacturer (here: Laser Vision) Protection Level L7 Range of Wavelength: 1050 nm to 1400 nm * Continous- and Puls Operation



The kind and the coverage of damages

depends on the wavelength, the laser power

and the exposure to radiation .

Skin damages

Normally curable

Eye damages

Normally incurable

Kinds of Damages



Units of the Electromagnetic Spectrum

Wave-length in meter(m)

Expression

Frequency In Hertz

(Hz)

10-12

Gamma Rays

1021

10-10

X-Ray

1018

10-9

to 10-6

Ultraviolet

Radiation (UV)

1016

10-6

to 10-3

Infrared

Radiation (IR)

1013

10-3

Millimeter Waves

1011

10-2

Centimeter Waves

(Microwaves)

1010

100

Meter Waves

(FM Radio + Television)

108

103

Kilometer Waves

(AM Radio)

105

400 nm

700 nm

VisibleSpectrum

Nd:YAG 1064 nm

CO2: 10600 nm



TechnologySolid-state lasers

Compact, stable, high beam quality,highly efficient pumping

Relatively inefficient pumping

Use a specially doped optical fiberGenerally use a laser rod

Solid-State Lasers

Air-cooling sufficientWater-cooling required

Fiber LasersNd:YAG Lasers

Use a solid as activating/ lasing medium (as opposed to gas like in CO2 lasers)

end mirror output coupler

lamp/ diode laser

Nd:YAG rodQ-switch

aperture

end mirror output coupler

lamp/ diode laser

Nd:YAG rodQ-switch

aperture

Source: A. Tünnermann, H. Zellmer, H. Welling, "Faserlaser" in Physikalische Blätter, November 1996

Laser diode +

Laser beam

Mirror

Lasing medium: fiber laser

Coupling optic



TechnologyFiber lasers: generals

Scheme of an end pumped fiber laser:

Laser Diode

Laser beam

Mirror

Lasing medium: fiber laser

Coupling optic



The Fibre

refraction indexpump core

laser core

The core of the fibre is Ytterbium doped and has a diameter of 10 µm.



The Laser Source 1

The Fibre Laser is operated in pulsed operation mod e.The following values can be reached:

LF100: YLP-C-1/100/10/10

LF200: YLP-C-1/100/20/20



The Laser Source 2 - Datasheet

1010sWarm up time (max.)

1055-10701055-1070nmWavelength

20-8020-80kHzPulse repitition rate

0-400-40°CEnvironment temperature range

10-9510-95%Humidity

4 build in fans4 build in fansCooling method

pulsedpulsedMode of operation

1.51.5Beam quality, M2 (typical)

65ACurrent consumption

23-2523-25VSupply voltage

10-10010-100%Output power adjustment range

19-219.5-11WNominal average output power

YLP-C-1/100/20/20YLP-C-1/100/10/10IPG name

LF200LF100UnitParameters



Function Principle of a vector scanning laser system



Excitation of Atoms

2.) spontaneous Emission

3.) stimulated Emission

Three important processes in activation of atoms:

1.) Absorption



Light Amplification (Avalanche Effect)

photonmoleculeThe first photon to start the avalanche, comes from the laser diode in the beam source.



Definition of the X- and Y- Axis



Working Distances and Marking Fieldsfor SHF60A



Working Distances and Marking Fieldsfor SHF100A



Focusing of the Laser Beam-Diameter of the focus point-

laser beam

Laser scan lens

Focal length

F

dFdL

Bd

Fd

LF •

•••=

πλ4

I (YAG) = 100 x I (CO 2)

dF (CO2) = 10 x dF (YAG)

F = Focal length (in mm)

dL = Diameter of the Laserbeam before the lens (in mm)

dF = Diameter of the beam in the focus (in mm)

λ = Wavelength (in nm)

B = Modefactor, B(TEM00)=1

I = Intensity (in W/mm2)



Structure of the Expansion Module (Telescope) I

Expansion lens- negative focal length F= -44mm- concave / flat

Collimating lens- positive focal length F= 90mm- flat / convex

Beam direction



Structure of the Expansion Module (Telescope) IIStandard Expansion Module for SHF- 100A:Beam Expansion Factor 2.0

Adjustment screw

Expansion lens Collimating lens



Assembly of the Beam Expansion (v=2.0)

Expansion lens Collimating lens

Standard Expansion Module for SHF- 100A:Beam Expansion Factor 2.0



dF: Diameter of the laser beam at the focus point

Definition:The depth of field is the area, where the diameter of the laser beam, is smaller than twice the focal diameter.

depth of field

dF 2 dF2 dF

laser beam

Knowledge: The bigger the beam expansion factor is, the smalle r the laser beam can be focussed.The bigger the beam expansion factor is, the bigger is the depth of field.The bigger the focal length is, the bigger is the d epth of field.

Focusing of the Laser Beam-Depth of field-



L Light

A Amplification by

S Stimulated

E Emission of

R Radiation

Definition



Software Training Smart Graph 6.x




Administration of Markingsystems 1



Administration of Markingsystems 2



Creating Templates

Template

Contents:- Text- Numbers- Date/time- Serial numbers- Logos- Lines- Geometrical objects- Barcodes- ID Matrix codes

Arrangement:- Positioning(X-,Y-coordinates)

- Rotation, mirroring,..- Text options

(scaling, ringmarking)

Parameter Set

Contents:- Marking intensity- Marking speed- Jump speed- Pulse frequency- Delays- cw-operation

Product-RegistrationContents:- Mark on the fly- Marking angle- Encoder operation- Light barrier, slope- Start distance- Triggering - Blockings



PC-database

(on the PC)

Online-database

(on the laser)

Function buttons

File-Menue



The Laser-Operation-Dialogue - Marking

System state

Informations about the current template



Rotation and positioning of the current template

Zoom toolsPreview of the current template

Select a template –leads to an instant change of the current template

Programs for the ext. template selection and for an ext. control of all templates used in the customer database.

The Laser-Operation-Dialogue - Marking adjustment



Display of error messages and warnings!!!

The Laser-Operation-Dialogue - Messages



Creating Templates 1- The template editor



Creating Templates 2- The main tool-bar



In the SmartGraph you can generate templates. One parameter set and one product registration, have to b e assignedto the new template.

Creating Templates 3- Assignment of parameter set and prod. registration

What is to be marked?

Select and edit theparameter set and theproduct registration.



Select Tool

polygon

ellipse, circle, arc

rectangle

text/date/time/SN/shift

logo

bar code

Id matrix code

Creating Templates 4- The tool bar list



Parameter Set DialogueHow shall the laser mark?- Which marking intensity (power)?- Which frequency?- Which mirror-and laser delays?



Product Registration DialogueWhen shall the laser start marking? (on moved or non-mov ed products)- With or without product movement? - With automtic consecutive trigger?- With light barrier detection (positive oder negative s lope)?- With fixed line speed or incremental encoder operation?



Marking Head DialogueWhich kind of laser components do you use?- Which kind of objective is mounted in your system?- Size of the galvanometers mirrors?- Mounting position of the laser head?- Do you use a tube?- Size of the marking field?



System Setting DialogueImportant software settings- Which IP-address has got my system?- Which system language is desired? - Date and time settings - Shall the pilot laser be active?

Standby Delay:- System state: Standby- Standard value: 600 s

Power Change Delay:(is not needed for CO2-Lasers)- System state: Prepare for marking- Standard value: 0 s



Application-Training




2. Stroke

Jump

Jump

Jump

Jumps and Strokes

Pulsed Stroke (magnified)



Lines with and without Crossings

Lines with crossings

Lines without crossings

Side view

Side view



Laserparameter – Marking Intensity -

The laserparameter marking intensity affects extrem ely the quality of the marking. It alters the power of the laser markingsy stem.The marking intensity is adjustable from 0 to 100 % .



Laserparameter - Pulse Frequency -

The pulse frequency is adjustable from 20-80 kHz If you want to increase the pulse frequency, it is only possible to do this in a certain range.When the range is exceeded, the max. acceptable val ue is displayed.



Marking Head Parameter - Jump Delay -

Jump Delay too short Vibration of the galvos at the beginning of a vector.

Jump Delay too longMarking time is prolonged unneccesarily.

Meaning: Break time after each jump.

Settings: standard: 200-300 µs (SHF-100A)minimum: 0 µsmaximum: 5000 µs

jump

line (marking)

vectors

stroke

jump delay



Laser Parameter - On Delay -

Meaning: The time between starting ofthe galvo mirrors at the beginning ofof a stroke and the turn-on of thelaser beam.

Settings: standard: -200 µs (negative!)minimum: -1000 µsmaximum: 1000 µs

On Delay too shortThe beam source is turn-on delayed. We need a negative On Delay for fibre lasers.

On Delay too longThe beginnings of the strokes are not marked,because the laser beam is turned-on too late.The galvo mirrors have been moved in the meantime.

jump

line (marking)

vectors

stroke

on delay



Marking Head Parameter - Stroke Delay -

Stroke Delay too shortThe galvo mirrors get the command, to jump to a new position, before they havereached the end of the stroke.

Stroke Delay too longMarking time is prolonged unneccesarily.

jump

line (marking)

vectors

stroke

stroke delay

Meaning: Break time at the endof each stroke.

Settings: standard: 150 µs (SHF-100A)minimum: 0 µsmaximum: 2000 µs



Laser Parameter - Off Delay -

Off-Delay too shortThe ends of the strokes are not marked, because the laser beam is turned-off tooearly. The galvo mirrors have not reachedtheir end positions.

Off-Delay too longAt each end of a stroke the laser beam burns into the material, because the laserbeam is turned-off too late. The galvo mirrors are already in their end position.

jump

line (marking)

vectors

stroke

off delay

Meaning: The time between stoppingof the galvo mirrors at theend of a stroke and the turnoff of the laser beam.

Settings: standard: 150 µs minimum: 0 µsmaximum: 1000 µs



Marking Head Parameter - Mark Delay -

Mark Delay too shortWith high marking speed, curves appearat the corners.

Mark Delay too longMarking time is prolonged unneccesarily.At each end of a vector, the laser beam burns into the material.(Exception: The last vector of a stroke.)

jump

line (marking)

vectors

stroke

mark delay

Meaning: Break time at eachminimum vector.

Settings: standard: 0 µs (SHF-100A)minimum: 0 µsmaximum: 999 µs




System Description



System Overview

Interface UnitSupply Unit

Marking Head



Data Transmission 1



Data Transmission 2



Data Transmission 3



The Supply Unit 1

S1/S2 Main switch: ON/OFF Starts the booting/shuts down the laser

S3 Key-operated switch: Applies the laser power for the beam source 0 = Laser is not ready to mark 1 = Laser is ready to mark

S4/S5 Start/Stop switch: Starts and stops the marking process.

L1 Laser is ready to mark or marking. The key-operated switch is in position ON, laser radiation can be released.

L2 Blinking: ErrorL3 Blinking: System is booting

Normal white: System is booted Bright white: System is marking

G55 Socket of the Handheld

L2

S3

S4/S5

L1 L3

S1/S2G55



The Supply Unit 2

24VACC-3

Fibre-Laser

source

24V/320W-Power-supply:- By connecting mains the

power supply is powered up (fan in the power supply is running).

- When the ON button is pressed, the relay on the interface board, connects the power supply to the interface board (system boots up).

Fibre-cable

Customerinterface

Ethernet-connection

FLEB+

Serial Interface RS232

Cable-gland

FM

Fan

Mains cable

Interface board

Marking head cable



The Marking Head (Pilot Laser+mirror)

Pilot Laser

Pilot Beam Turning MirrorMounted on a solenoid

Axis

Beam shutter



The Marking Head (Scanner mirrors)

Y-Mirror

X-Mirror




Hardware Training



Hardware Overview

Data and signal processing of the laser system



Data and signal processing



Technical Data 1



Technical Data 2



The Interlock Circuit

Under construction…



System States 1Initialize

Error acknowledge

main switch OFF and ON again

acknowledge

Interlock open Laser ready

Key-switchopen

Fatal Error

Stand-byafter 10 min.

start

Start

stop

System OFF main switchON

close key- switch

Laser start up

Prepare for marking

Wait for trigger

Markingstop

stop

stop



System States 2



Timing-Diagram 1



Timing-Diagram 2



Timing-Diagram 3



The ACC-3Advanced C ontroler C ard-3 (Index J and higher):

X1: 30 V Power

jumper placed : 12V for Customer I/O

jumper not placed: 24V for Customer I/O

Dip- Switch 1:Sets IP-adress 192.168.1.1Subnet-Mask:255.255.0.0DIP-Switch 2: no function



The ACC-3Function of the LEDs – 1 – Index F















The Backup-Battery on the ACC-3 board

The battery buffers the following dynamic datas, in the SRAM (128 KB) on the ACC-2 board:• The last used template

• Dynamic datas for all templates (e.g.: serial numbe rs, variables, shift codes, etc.)

• Time and date (the clock even runs if the laser is switched off)

• Error warnings and messages

If the laser is switched off, the lifetime of the battery is approximately 1.5 - 2 years. If the laser is switched on, the lifetime is approximately 3-5 years. That means, the longer the laser is switched on, the longer is the lifetime of the battery.When the battery is empty, an error warning will be generated.



The MMC Card – M ulti M edia Cardon the ACC-3 board

On the MMC the following datas are permanently stor ed:- Customer database- Component files (laser, markinghead, lens)- Operating system (Linux, AOS)- Processor- and board software (FPGA, FM, ACC-3)

An operating system update, and an update of logics or component files, can be easily done, by exchanging the MMC, when the system is switched off. A renewed booting of the system, happens already with the new software releases.



Programming of the MMC



The Interface Board

- The Interlock circuit is switched on the Interface board.- Voltage converter, generates 24V to -24V.




The FM BoardThe Fast Move Board (Index M and higher)

• The FM-board is inside the supply unit.

• Digital scanners are manufactured by Cambridge Tech nologies.

They are made of silicium and covered with dielectr ical layers.

• On board is an EEPROM, which contains deflection sy stem datas.

• In case of an error the FM-board has to be exchanged together with both mirrors.

• The copper cooling plate carries -24V.

Power consumption FM Board : 300 Watt



The FLEB+The Faser L aser Extension B oard




The Membrane Board




The Customer Interface





Incremental Encoder

Connector X7

Light Barrier/Initiator

Connector X6

CAN-Bus

Connector X14

Interlock Circuit

Connector X2

Digital Inputs

Connector X20

Digital Outputs

Supply Voltage for digital I/O 12/24 V

Connector X16












Standard Connection to Lightbarrier and Encoder



The external customer interfacefor ext. template selection via CAN-BUS and PLC

Data 0-7 plus ext. event



Timing Diagram 4- External template selection



Calculation of the max. availableMarking time for single line marking

E X P : 1 2 . 2 0 0 8

60 mm 140 mm

Product movement

Length of the marking Length of the marking field

200 mm = 0,2 m

Vproduct = 9 km/h = 9 km x 1000 m h

3600 s Vproduct = 2,5 m/s

max. availabe marking time:

tmax = 0,2 m s = 0,08 s = 80 ms2,5 m

Example:



1. Select the template with the current parameter set and the current product registration. The size of the square and the marking time should corresp ond to the template bemarked later on. The marking time can be displayed with the info-button in the template. Don‘t forget to set the correct laser power.

2. Start the test. When the square opens or closes in line direction, the distance per rotation of the incremental encoder has to be changed, in the field: “Distance/Rot.“ .

Square opens in line direction.Remedy/measure: Distance per rotation must be decreased !

Square closes in line direction.Remedy/measure: Distance per rotation must be increased !

Compensation of the Movement 1(Mark On The Fly – MOTF)

Product movement



Square opens in laser direction.

Remedy/Measure:Angle must be increased !

When the square opens or closes in direction of the laser, the angle has to be changed inthe field:“Angle between laser axis and direction of product moveme nt “.

Important: First mark the square without product movement, to make sure that the parameter ‘on-delay‘ is setted correctly!

Square closes in laser direction.

Remedy/Measure:Angle must be decreased !

Product movement

Compensation of the Movement 2(Mark On The Fly – MOTF)



The Handheld G55




The Handheld G55

Lighted Display with WYSIWYG-view

POE-Port (Power Over Ethernet)

Funktion Buttons

Alphanumeric Keypad

Shock Proofed Body

F1 F2 F3 F4 F5



The Handheld G55 - User Levels - 1



The Handheld G55 - User Levels - 2

6. View alert history7. View alert history4. View error warnings

6. System settings- Set time and date

5. Modify, delete and copy parametersets and product registrations

5. Modify, delete and copy templates, parameter sets and

product registrations

4. Create new parameter sets and product registrations

4. Create new templates, parameter sets and product registrations

- Set time and date- Change unit of measurement- Change handheld language- Change system language- Change IME (special characters)- Network setup (IP-adresses)- Markinghead adjustment- Pilotlaser adjustment- Change G55 passwords

3. Adjust marking- Set Variables- Rotation- X-Offset- Y-Offset- Laser power- Marking speed- select current product

registration

3. Adjust marking- Set Variables- Rotation- X-Offset- Y-Offset- Laser power

4. System settings 2. Select current template2. Select current template

1. - 3. Same as in technician level1. Store database1. Store database

AdministratorTechnicianOperator



The Handheld G55 - The Keypad



The Handheld G55- used Symbols (via Funktion Buttons) - 1



The Handheld G55- used Symbols (via Funktion Buttons) - 2



Maintenance and Inspection




The Maintenance Plan

Monthly:• Check the laser scan lens for dust and dirt. Clean the laser scan lens

incase of dust or stains.

Monthly or when control lamp lights up:• If installed: Exchange the filter bag inside the exhaust unit

(refer to manual the exhaust unit).

Every three months (more frequently when oprated in dirty ambient conditions):• Carry out a visual inspection of the laser system.

Every six months:• If installed: Exchange the charcoal filter inside the exhaust unit

(refer to manual of the exhaust unit).



Cleaning the Laser Scan Lens



ALLTEC - ContactIf you need help ...

... please contact our Service-Hotline: Tel. +49-(0)38823-55-360

We are available for your support from 06:00 to 18:00 from Monday to Friday!

If for any reason it is impossible to connect you directly with our service technician, you are automatically connected to our answer phone. Please provide the followinginformation:

• your name

• name of your company

• your telephone number!

• the reason for your call

We will return your call a.s.a.p.!

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