Home / News / Maintenance of Laser Welding Machine

Maintenance of Laser Welding Machine

Views: 857     Author: Site Editor     Publish Time: 2023-12-18      Origin: Site

Inquire

facebook sharing button
twitter sharing button
line sharing button
wechat sharing button
linkedin sharing button
pinterest sharing button
whatsapp sharing button
sharethis sharing button

Table of Contents

1. Introduction

2. Basic Working Principle of Laser Welding Machine

2.1 Components of laser welding machine

2.2 Overview of the laser welding process

3. Importance of Laser Welding Machine Maintenance

4. Daily Maintenance Steps

5. Regular Maintenance Recommendations

6. Common Faults and Their Solutions

7. Safety Precautions

8. Summarize


Introduction

In modern manufacturing, laser welding machines have become an indispensable advanced equipment. With the continuous development and innovation of technology, laser welding technology has been widely used in various fields, including automobile manufacturing, aerospace, electronic products, medical equipment, etc., due to its high efficiency, precision and strong adaptability. The laser welding machine generates high temperature on the surface of the material by concentrating the laser beam, causing it to melt rapidly, thereby completing the welding process. Compared with traditional welding methods, laser welding has a smaller heat-affected zone, higher welding quality and lower material deformation, which can meet the higher requirements of modern production for precision and efficiency.


However, the efficient operation of the laser welding machine is inseparable from regular and effective maintenance. Maintaining the welding machine can not only ensure the stability and safety of the equipment in a high-intensity working environment, but also improve production efficiency, reduce the failure rate, and reduce unnecessary downtime. By regularly inspecting and maintaining the laser welding machine, the company can ensure that the equipment is always in the best working condition, thereby maximizing its potential and optimizing the production process. In addition, good maintenance can also extend the service life of the equipment, reduce long-term operating costs, and have a positive impact on the economic benefits of the enterprise. Therefore, establishing a systematic laser welding machine maintenance plan is an important strategy for every manufacturing company to achieve sustainable development.

Basic Working Principle of Laser Welding Machine

Laser welding machine is a device that uses laser beam as heat source for welding. Its basic working principle is to irradiate the surface of the material to be welded with a high-energy density laser beam, so that the material is quickly heated to the melting point and a heat pool is formed during the melting process. When the laser beam moves over the material, the molten metal flows and cools, and finally forms a strong weld joint. This process not only enables high-quality welding, but also accurately controls the welding depth and welding speed to meet the welding needs of different materials and thicknesses.

Maintenance of laser welding machine features-Suntop

1. Components of laser welding machine

Laser welding machine is mainly composed of the following components:

Laser: The core component of the laser welding machine, responsible for generating a high-intensity laser beam. Common types of lasers include fiber lasers, CO₂ lasers, and YAG lasers.

Optical system: It consists of lenses and mirrors, which are responsible for focusing the laser beam and guiding it to the welding position. The design of the optical system affects the quality of the laser beam and the accuracy of the welding.

Motion control system: It includes a robotic arm, a drive system, and control software to accurately control the position, welding path, and speed of the laser.

Cooling system: Ensure that the laser and optical components are maintained at an appropriate temperature during operation, usually using water cooling or air cooling.

Safety protection devices: including laser protective covers, alarm systems, etc., to ensure the safety of operators and prevent lasers from causing damage to the surrounding environment and personal safety.


2. Overview of the laser welding process

The laser welding process can generally be divided into the following main steps:

Preparation: Ensure that the surface of the material to be welded is clean, remove oxides and impurities to improve the welding quality.

Laser beam standardization: The laser is started and the laser parameters (such as power, frequency and spot size) are adjusted according to the welding thickness and material type.

Welding starts: The laser beam is focused on the gap to be welded, and the laser energy instantly heats the material to form a molten pool.

Laser movement: The motion system of the laser or workpiece moves according to the pre-set welding path, and the laser beam welds on the gap at a certain speed.

Molten pool solidification: As the laser beam moves, the molten pool gradually solidifies to form a welded joint. At this time, the cooling rate and welding depth of the material can be adjusted in real time to obtain the best welding performance.

End of welding: The laser is turned off, welding is completed, and the welded joint reaches the expected strength after proper cooling.

Post-processing (optional): Clean, inspect or perform subsequent process treatment on the welded joint to ensure that the welding quality meets the requirements.


Laser welding machines have become an indispensable part of modern manufacturing processes due to their high efficiency and precision, and are widely used in various industries.

Importance of Laser Welding Machine Maintenance

As a high-precision welding equipment, laser welding machine plays an important role in modern manufacturing. In order to ensure its long-term and stable operation, regular maintenance is particularly important. The following is the importance of laser welding machine maintenance:


1. Improve the working efficiency of the equipment

Regular maintenance of the laser welding machine can ensure that the equipment operates in the best condition, reduce the failure rate, and reduce unexpected downtime. By checking and adjusting the performance of the laser, the cleanliness of the optical system, the accuracy of the motion control system, etc., the efficient operation of the equipment can be maintained. Once there is a problem with the equipment, it may lead to a decrease in welding speed and welding quality, thus affecting the entire production process. Therefore, regular maintenance can not only improve the working efficiency of the equipment, but also improve the overall operation efficiency of the production line.

Maintenance of laser welding machine sample-Suntop

2. Extend the service life of the equipment

As a high-value equipment, the maintenance of the laser welding machine is directly related to its service life. Regular maintenance and inspection can detect potential problems in time and prevent small faults from developing into major faults. In addition, a reasonable maintenance plan can reduce mechanical wear and material aging, thereby extending the overall service life of the equipment and reducing the long-term operating costs of the enterprise. By extending the service life of the equipment, the enterprise can improve the return on investment to a certain extent.


3. Ensure production quality and safety

The quality of laser welding directly affects the performance and reliability of the product. During the maintenance process, the calibration of the laser welding machine, the cleaning of the optical part, and the stability of the laser beam are checked to effectively ensure the consistency and strength of the welded joint. In addition, good maintenance can also reduce the safety hazards caused by equipment failure and ensure the safety of operators. Preventive maintenance measures can help avoid accidents caused by equipment failure and ensure the smooth progress of the production process.


Regular maintenance of laser welding machines is of great significance to improving work efficiency, extending the service life of equipment, and ensuring production quality and safety. Enterprises should attach importance to maintenance work and formulate systematic maintenance plans to achieve the best operating state of equipment, thereby improving production efficiency and market competitiveness. Click here for more information on laser welding now!

Daily Maintenance Steps

Daily maintenance of laser welding machines is an important part of ensuring efficient and safe operation of the equipment.


1. Clean the outside of the equipment:

Clean the outer shell of the laser welding machine with a damp cloth regularly to remove dust and impurities and keep the appearance of the equipment neat and tidy.


2. Check the optical system:

Observe whether the optical components (such as lenses and mirrors) are dirty or damaged. If necessary, use special cleaning agents and dust-free cloths to clean to ensure the quality of the laser beam.

Maintenance of laser welding machine samples-Suntop

3. Laser inspection:

Regularly check the working status and cooling system of the laser to ensure that the cooling water temperature and flow are normal, and exhaust in time to prevent bubbles from affecting the cooling effect.


4. Optical path alignment:

Ensure the focusing and alignment accuracy of the laser beam. If deviation is found, it should be adjusted. Correct alignment of the optical path helps improve welding quality.


5. Motion system inspection:

Check whether the robot arm and its moving parts are well lubricated to ensure that all moving parts move smoothly. If necessary, add lubricating oil to avoid mechanical wear.


6. Check the electrical system:

Check the cables and connectors to ensure that they are not loose or worn to prevent short circuits and equipment failures.


7. Monitoring software and settings:

Regularly check and update the software system of the laser welding machine to ensure the accuracy of control parameters and data. At the same time, record the welding settings for subsequent reference.


8. Safety protection device inspection:

Ensure that the laser protection cover, emergency stop button and safety alarm system are working properly. Regular inspection of these protective devices can effectively protect the safety of operators.


9. Regularly record maintenance logs:

Record the content, date and problems found in each maintenance to facilitate tracking of equipment status and arrange subsequent maintenance or overhaul plans.


10. Train operators:

Ensure that operators understand the basic maintenance steps and precautions of the equipment, improve their safety awareness, and avoid equipment damage caused by improper operation.


Regular routine maintenance can not only improve the working efficiency and extend the service life of the laser welding machine, but also ensure welding quality and operational safety. It is recommended to formulate a detailed maintenance plan based on the recommendations of the equipment manufacturer and actual use to ensure that each maintenance work can be implemented in a timely and effective manner. Click here for more information on laser welding now!

Regular Maintenance Recommendations

In order to ensure the efficient operation and long-term stability of the laser welding machine, regular maintenance is recommended. The following is a maintenance plan for monthly/quarterly and annually:


1. Monthly/quarterly maintenance plan

● Check the power system and control panel:

Make sure the power connection is firm, and check whether the power cord and socket are aged or damaged.

Check whether the buttons on the control panel are sensitive, whether the indicator lights are working properly, and make sure that there are no abnormalities in the settings on the control interface.

● Update software and firmware:

Regularly check and update the software and firmware of the laser welding machine to ensure that the system has the latest functions and security patches. You can visit the manufacturer's official website to obtain the latest version and install it accordingly.

● Check the cooling system:

Check the level and quality of the coolant to ensure that there are no contaminants, and replace the coolant if necessary.

● Clean the optical components:

Regularly check and clean the optical components (lenses and reflectors) to maintain the quality of the laser beam.

● Check the motion system:

Check the lubrication of moving parts such as the robot arm and guide rails, and add lubricating oil or grease if necessary.

Air-cooled Laser Welding Machine samples-Suntop

2. Annual comprehensive overhaul projects

● Calibration and adjustment of the entire system:

Comprehensively check and calibrate the laser output power, optical path alignment and focusing accuracy to ensure welding quality and efficiency.

● Replace worn parts:

Inspect and replace worn or aged parts according to the use of the equipment, including but not limited to the laser lens, optical fiber, bearings and seals of the motion system.

● Check the safety system:

Check the safety protection device to ensure that all safety functions are working properly, including laser protection, emergency stop button and alarm system.

● Comprehensive performance test:

Conduct a comprehensive performance test to ensure that the equipment is operating in the best condition, including verification of output power, welding speed and quality.

● Clean and maintain external components:

Thoroughly clean the outside of the equipment, including fans, exhaust systems, etc., to prevent dust accumulation from affecting the heat dissipation of the equipment.


Regular maintenance and care are important means to ensure efficient and stable operation of the laser welding machine. By formulating detailed monthly/quarterly maintenance plans and annual comprehensive overhaul projects, faults can be effectively prevented, equipment life can be extended, and welding quality and production safety can be improved. It is recommended that enterprises record detailed information on each inspection and maintenance during the maintenance process to track equipment history and formulate follow-up plans. Click here for more information on laser welding now!

Common Faults and Their Solutions

The laser welding machine may encounter some common faults during use. Here are some common faults and their solutions for your reference:


1. The laser does not emit laser

Fault cause:

Power problem

Laser failure

Control system abnormality

Solution:

Check the power line and socket to ensure that the power connection is normal.

Check the status indicator of the laser. If there is a fault code, refer to the manual.

Restart the control system and check whether the relevant settings are correct.


2. Poor welding quality

Fault cause:

Improper welding parameter setting

Optical component contamination

Workpiece surface contamination

Solution:

Adjust parameters such as welding power, speed and focal length according to the material and thickness.

Clean the optical components (lenses and reflectors) to ensure the quality of the laser beam.

Make sure the surface of the workpiece to be welded is clean and free of impurities such as oil, rust, etc.


3. Cooling system failure

Fault cause:

Coolant leakage

Cooling pump failure

Insufficient coolant

Solution:

Check whether there is water leakage in each component of the cooling system and repair it in time.

Check the operating status of the cooling pump and replace or repair the pump if necessary.

Add enough coolant and ensure that its quality meets the requirements.


4. Laser beam deviation

Fault cause:

Improper alignment of optical path

Damage or contamination of optical components

Solution:

Realign the optical path to ensure that the laser passes smoothly through the lens and reflector.

Check the status of the optical components and clean or replace them if necessary.


5. Motion system stuck

Fault cause:

Wear of mechanical parts

Insufficient lubrication

Solution:

Check each part of the motion system and replace the worn parts in time.

Regularly add lubricating oil or grease to the moving parts to ensure smooth movement.


6. The control panel is unresponsive

Fault cause:

Software failure

Hardware failure

Solution:

Try to restart the device to see if the control panel responds again.

Check for software updates and upgrade if necessary.

If the problem persists, contact professional technicians for inspection.


7. Abnormal noise

Fault cause:

Wear of mechanical parts

Collision or interference of physical objects

Solution:

Check the source of noise, check the mechanical parts and transmission system.

Make sure that there are no foreign objects in the working area that interfere with the operation of the equipment.


For common faults of laser welding machines, timely troubleshooting and treatment are the key to ensuring the normal operation of the equipment. In daily operation, operators should improve their ability to identify faults and perform regular maintenance and upkeep to reduce the occurrence of equipment failures. If you encounter a problem that cannot be solved, it is recommended to contact professional maintenance services in a timely manner. Click here for more information on laser welding now!

Safety Precautions

Safety is very important when using laser welding machines and related equipment. Here are some common safety precautions:


1. Personal Protective Equipment (PPE)

Goggles: Always wear goggles designed for laser welding to prevent laser beam damage to the eyes.

Protective clothing: Wear heat-resistant and fire-resistant work clothes, and avoid wearing clothes made of flammable materials.

Gloves: Wear heat-resistant and wear-resistant gloves to protect your hands from high temperatures and sharp metal edges.


2. Working environment

Good ventilation: Ensure that the work area is well ventilated and harmful gases and fumes are removed.

No flammable items: The workplace should be kept away from flammable and explosive items to prevent accidents.

Neat and tidy: Keep the work area tidy and avoid accumulation of debris to reduce the risk of accidents.


3. Equipment operation

Be familiar with the operating manual: Before using the laser welding machine, carefully read and understand the safety instructions in the operating manual.

Equipment inspection: Before turning on the machine, check whether all parts of the equipment are normal and ensure that there is no damage.

Follow the operating procedures: Operate strictly in accordance with the operating procedures and do not change the settings at will.


4. Laser safety

Warning signs: Areas where laser welding machines are used should be marked with obvious warning signs to remind others to pay attention to safety.

Taboos: Do not look directly into the laser beam: Do not look directly into the laser beam, including reflected light, to avoid visual damage.

Avoid random activation: Make sure the laser is turned off before you are ready to work to avoid accidental activation.


5. Emergency response measures

Confirm the emergency stop device: Make sure you are familiar with the location of the emergency stop device at the work site and can use it quickly.

Develop an emergency plan: Develop an accident emergency plan and organize drills regularly to improve emergency response capabilities.

Contact medical services: If an accident occurs, seek medical help in a timely manner and report the accident.


6. Regular training

Employee training: Conduct safety training for operators regularly to improve safety awareness and emergency response capabilities.

Update knowledge: Keep abreast of new knowledge on laser technology and safe operation to ensure knowledge is updated.


When operating a laser welding machine, you must strictly follow all safety regulations to protect yourself and others. In actual work, always maintain a high degree of vigilance and professionalism to ensure operational safety. Click here for more information on laser welding now!

Summarize

Maintaining welding machines is essential to ensure the efficient operation of equipment and welding quality. Regular maintenance can not only extend the service life of the equipment, but also effectively reduce the frequency of failures, thereby reducing maintenance costs and downtime. Good maintenance measures can detect potential problems in a timely manner, ensure that the welding machine operates in the best condition, improve production efficiency, and maintain the consistency of welding quality. In addition, maintenance work also involves safety. Regular inspection and maintenance can reduce safety hazards caused by equipment failure and ensure the safety of operators.


Therefore, it is particularly important to encourage enterprises to establish a complete maintenance plan. A systematic maintenance plan should include regular inspection, cleaning, calibration, lubrication and replacement of wearing parts, and incorporate these steps into daily operating procedures. By establishing maintenance records, enterprises can analyze the performance changes of equipment and provide data support for future maintenance. At the same time, enterprises should also train operators to improve their maintenance awareness and skills to ensure that maintenance measures can be effectively implemented. In this way, enterprises can not only improve production efficiency and reduce operating costs, but also ensure the safety and reliability of equipment, thereby maintaining their advantages in the fierce market competition.

Leave a Message
Contact us
More than 10 precision production line, easy to realize large quantities of goods, to provide you with the best price.
Contact Us
  No 317, Mu Dong RD, Wu Zhong DIST, Suzhou City, Jiangsu Province, China
 info@suntoplaser.com
  +86 13771746401

Products

Quick Links

© 2023 Suzhou Suntop Laser Technology Co., Ltd  All rights reserved.