Modern Intelligent Laser Processing System

Laser processing is a method that uses laser energy to melt and then shape materials. Depending on the purpose of the process, it can be categorized as laser cutting, laser marking, laser welding, laser cladding, and laser additive manufacturing. Laser temperatures can reach 6000°C, instantly melting or even vaporizing the material. As a typical thermal process, it is known for its minimal heat-affected zone, fast processing speed, and the absence of post-processing requirements. It is particularly suitable for thin plates or materials that are easily deformed by heat. Considering the safety and efficiency of laser processing, laser processing often utilizes automated production support to efficiently complete the task.

The foundation of laser processing is the laser processing system. A complete laser processing system includes a laser (including optical fiber, chiller, and regulated power supply), a laser head, a motion mechanism (robot or machine tool), a work platform, and other auxiliary equipment (industrial computer, cold dryer, auxiliary water vapor, etc.). The following briefly describes the laser, laser head, and motion mechanism.

The laser is the core of laser processing. Currently, fiber lasers are primarily used, offering excellent beam quality, high electro-optical conversion efficiency, and are maintenance-free, making them suitable for processing a wide range of materials.

Currently, mainstream lasers include CO2 lasers, fiber lasers, semiconductor lasers, and disk lasers.

The primary characteristic of lasers is their single-directional nature. This allows them to be optically transmitted to produce beams of varying sizes, making them suitable for different processing applications. Furthermore, the laser's concentrated energy provides strong penetration, making it suitable for processing thick plates.

The laser processing system's motion mechanism is composed of mechanical motion adapted to the structural characteristics of the workpiece. Machine tools are typically used for processing, and the current mainstream processing method is machine tool processing. Machine tool processing offers high precision and stability, primarily used for two-dimensional processing, including laser marking, laser cutting, and laser cladding. Robotic arms offer flexibility and facilitate three-dimensional processing, including 3D laser cutting and laser welding. While the processing precision is comparable to that of machine tools, they offer greater flexibility and a relatively small footprint.

The laser head is the terminal device that outputs the light energy during laser processing. It expands the laser beam through a combination of optical lenses and then amplifies it. Lasers can be categorized by their function, including laser cutting heads, laser welding heads, laser cladding heads, scanning laser heads, and laser marking heads.

Ordinary laser cutting heads have an air blow nozzle that uses high pressure to remove the laser-melted material, thus forming the kerf. The laser brazing heads currently used in automotive factories feature an automatic laser focusing function, which further enhances the stability of the laser processing. Scanning laser heads utilize lens angle rotation and position movement to maintain a constant laser spot size on the workpiece. Furthermore, through precise control, they can achieve welds in circular, straight, and C-shaped structures without changing the laser head's position.

What is Laser Cutting?

Laser cutting technology is widely used in the processing of both metal and non-metal materials, significantly reducing processing time, lowering processing costs, and improving workpiece quality.

Modern lasers have become the legendary "sword" that can "cut through iron like mud." Taking a laser cutting machine as an example, the entire system consists of a control system, motion system, optical system, water cooling system, fume exhaust and air blow protection system, etc. It utilizes the most advanced CNC mode to achieve multi-axis linkage and constant laser energy cutting regardless of speed. It also supports graphics formats such as DXP, PLT, and CNC, and enhances interface graphics processing capabilities. It utilizes high-performance imported servo motors and drive guide structures to achieve excellent motion precision at high speeds.

Laser cutting is achieved by utilizing the high-power density energy generated by focused laser light.

Under computer control, the laser discharges through pulses, outputting controlled, repetitive, high-frequency pulses of laser light, forming a beam of a specific frequency and pulse width. This pulsed laser beam is guided and reflected through an optical path, and then focused by a focusing lens assembly onto the surface of the workpiece, forming a fine, high-energy-density spot. The focal spot is located near the workpiece, melting or vaporizing the material at an instantaneous high temperature. Each high-energy laser pulse instantly sputters a tiny hole in the surface of an object. Under computer control, the laser processing head and the material being processed continuously move relative to each other according to a pre-drawn pattern, producing the desired shape. During cutting, a stream of air, coaxial with the beam, is ejected from the cutting head, displacing the molten or vaporized material out the bottom of the cut. (Note: If the air reacts thermally with the material being cut, this reaction provides additional energy for cutting. The airflow also cools the cut surface, reduces the heat-affected zone, and protects the focusing lens from contamination.)

Compared to traditional sheet metal processing methods, laser cutting offers advantages such as high cutting quality (narrow kerf width, small heat-affected zone, and smooth cut), high cutting speed, high flexibility (capable of cutting any shape), and wide material compatibility.