Design and Manufacturing of Portal Laser Welding Equipment

The portal column laser welding equipment is designed for high-precision welding tasks. It features a robust structure with high rigidity, ensuring stability during operation. The machine offers an effective stroke of 800 mm (X-axis), 600 mm (Y-axis), and 400 mm (Z-axis), with positioning accuracy of ±0.03 mm for X and Y axes, and ±0.02 mm for the Z-axis. The laser system, with a power of up to 3000W and a wavelength of 1070 nm, provides adjustable focus and spot sizes to accommodate various materials and thicknesses. The equipment supports dual-station switching for enhanced efficiency and is equipped with a user-friendly CNC control system. Safety features include emergency stop buttons and protective covers. Regular maintenance ensures long-term reliability and performance.

I. Design Indicators

(1) Welding Precision

• Positioning Accuracy:
• X-axis: ±0.03 mm
• Y-axis: ±0.03 mm
• Z-axis: ±0.02 mm
• Repeatability:
• X-axis: ±0.05 mm
• Y-axis: ±0.05 mm
• Z-axis: ±0.02 mm

(2) Processing Area

• Worktable Dimensions:
• Standard size: 1300 mm × 1100 mm × 2200 mm
• Customizable size: Up to 2000 mm × 1500 mm based on customer requirements
• Dual-Station Design: Supports dual-station switching to enhance equipment utilization and production efficiency.

(3) Welding Speed

• Rapid Positioning Speed:
• X-axis: 60 m/min
• Y-axis: 60 m/min
• Z-axis: 15 m/min
• Welding Speed Range: 0.25 m/min – 1.5 m/min, adjustable.

(4) Laser Performance

• Laser Parameters:
• Wavelength: 1070 nm
• Fiber core diameter: 50 μm
• Beam quality: M² < 0.373
• Power adjustment range: 0% – 100%
• Fiber length: 15 meters
• Laser Mode: Continuous/Modulated
• Cooling Method: Water-cooled
• Focal Length: 180 mm
• Focus Adjustment Range: -5 mm to +5 mm

(5) Equipment Stability

• Rigidity Design: Utilizes high-strength steel and a portal column structure to ensure overall equipment rigidity.
• Long-term Stability: Good stability for 24-hour continuous operation, with power fluctuation less than ±5%.

II. Parameters

(1) Mechanical Parameters

• Worktable Dimensions:
• Standard size: 1300 mm × 1100 mm × 2200 mm
• Customizable size: Up to 2000 mm × 1500 mm based on customer requirements
• Effective Stroke:
• X-axis: 800 mm
• Y-axis: 600 mm
• Z-axis: 400 mm
• Transmission System:
• X-axis: TBI ball screw, precision grade P3, pitch 10 mm
• Y-axis: TBI ball screw, precision grade P3, pitch 10 mm
• Z-axis: TBI ball screw, precision grade P3, pitch 5 mm
• Motor: High-response servo motor, power 3 kW, speed 3000 rpm
• Guide Rail System:
• X-axis: Linear guide rail, model HIWIN HG20CA, stroke 800 mm
• Y-axis: Linear guide rail, model HIWIN HG20CA, stroke 600 mm
• Z-axis: Linear guide rail, model HIWIN HG15CA, stroke 400 mm

(2) Laser Parameters

• Laser:
• Model: Fiber Laser 3000W
• Power: 3000 W
• Operation Mode: Continuous/Modulated
• Cooling Method: Water-cooled
• Fiber Length: 15 meters
• Optical System:
• Focal Length: 180 mm
• Focus Adjustment Range: -5 mm to +5 mm
• Spot Diameter: Adjustable from 0.2 mm to 2.0 mm
• Laser Mode:
• Continuous Mode: Suitable for thick plate welding
• Modulated Mode: Suitable for thin plate welding and precision processing

(3) Electrical Parameters

• Power Supply:
• Voltage: 380 V
• Frequency: 50 Hz
• Rated Power: ≤ 19.8 kW
• Control System:
• CNC System: FANUC 0i-MF, supports 3-axis联动
• Operation Interface: Touchscreen operation, supports multiple programming languages
• Safety System: Emergency stop button, protective cover interlock device

III. Design Highlights

(1) Structural Design

• Portal Column Structure:
• Utilizes high-strength steel to ensure overall equipment rigidity.
• The columns and beams are welded structures, treated with heat and vibration to eliminate internal stress.
• The worktable is designed with thick steel plates, with a surface that is precisely machined for flatness and wear resistance.
• Dual-Station Design:
• Supports dual-station switching to enhance equipment utilization and production efficiency.
• Station switching time is less than 30 seconds, with switching accuracy of ±0.1 mm.

(2) Transmission System Design

• High-Precision Ball Screw Transmission:
• Selects TBI ball screws, precision grade P3, to ensure transmission accuracy.
• Equipped with high-response servo motors, power 3 kW, speed 3000 rpm, response time less than 1 ms.
• Linear Guide Rail System:
• Selects HIWIN linear guide rails, models HG20CA and HG15CA, to ensure smooth movement.
• Guide rail installation accuracy requirements: parallelism ±0.02 mm, perpendicularity ±0.02 mm.

(3) Laser System Design

• Laser Selection:
• Selects a 3000W fiber laser, suitable for welding various materials.
• Laser wavelength 1070 nm, fiber core diameter 50 μm, beam quality M² < 0.373.
• Optical System Design:
• Equipped with high-precision focusing and protective mirrors, focal length 180 mm.
• Spot diameter adjustable from 0.2 mm to 2.0 mm, suitable for welding different thickness materials.
• Cooling System:
• Uses a water-cooling system to ensure stable operation of the laser at high power.
• The cooling system has temperature monitoring and alarm functions to prevent the laser from overheating.

(4) Control System Design

• CNC System:
• Selects the FANUC 0i-MF CNC system, supporting 3-axis联动.
• Supports multiple programming languages, including G-code and ISO code.
• Operation Interface:
• Equipped with a 10.4-inch touchscreen operation interface, simple and convenient to operate.
• Supports multiple welding modes, including continuous and modulated modes.
• Safety System:
• Equipped with an emergency stop button and protective cover interlock device to ensure operational safety.

IV. Precautions

(1) Safety Protection

• Protective Devices:
• The equipment is equipped with a protective cover to prevent laser radiation from harming operators.
• The protective cover is made of transparent material for easy observation of the welding process.
• Emergency Stop:
• The equipment is equipped with an emergency stop button, located conveniently for operators to quickly operate.
• When the emergency stop button is pressed, the equipment immediately stops all movements and laser output.

(2) Working Environment

• Environmental Requirements:
• Working environment temperature: 10℃ – 35℃
• Relative humidity: 30% – 80%
• Surrounding environment: Well-ventilated, no impact sources within 5 meters.
• Power Supply Requirements:
• Power voltage: 380 V
• Power frequency: 50 Hz
• Grounding type: Direct grounding, grounding resistance less than 4Ω.

(3) Maintenance and Care

• Regular Checks:
• Check the cooling system daily to ensure sufficient coolant and no leakage.
• Check the fiber connections weekly to ensure they are secure and not loose.
• Check the lubrication of the transmission system monthly and add lubricating oil in time.
• Cleaning and Care:
• Regularly clean the optical mirrors to prevent dust and oil from affecting laser output.
• Regularly clean the worktable and guide rails to prevent foreign objects from entering the guide rails and affecting movement accuracy.

(4) Operator Training

• Operator Training:
• Operators must undergo professional training to be familiar with the operation process and precautions of the equipment.
• Training content includes the basic principles of the equipment, operating procedures, safety protection, and troubleshooting of common faults.
• Operation Manual:
• Provide a detailed operation manual, including equipment installation, commissioning, operation, and maintenance.
• The operation manual should include detailed parameters and precautions of the equipment for easy reference by operators at any time.

V. Various Tables

(1) Product Parameters Table

(2) Machine Technical Parameters Table

(3) Laser Parameters Table

(4) Working Environment Requirements Table

(5) Maintenance and Care Table

The above content covers the detailed design indicators, parameters, design highlights, precautions, and various tables for the portal column laser welding equipment. I hope this is helpful. If you have more specific requirements or need further refinement, please let me know.