大功率横流CO2激光器升级改造项目.doc

大功率横流CO2激光器升级改造项目Power Cross-Flow CO2 Laser Upgrading Projects1 项目概要通过对国内大功率横流CO2激光器使用单位的调查和技术分析，结合我公司在横流CO2激光器方面的技术优势，我公司决定开展部分在线激光器的升级改造项目。希望与各激光设备的使用单位进行充分的技术交流，通过技术服务，对激光设备的关键部位进行技术改造。一方面，可大幅提升激光器的输出功率（1.52倍）和运行稳定性，提高常规激光淬火和激光熔覆加工业务的生产效率；另一方面，可提高低阶模的输出效率，充分发挥大功率横流CO2激光器的加工潜力，帮助国内各激光加工单位拓展激光加工领域，如激光焊接。1 IntroductionThrough the cross-flow of domestic high-power CO2 laser units use the investigation and technical analysis, the combined company in the cross-flow CO2 lasers technical superiority, I decided to conduct some on-line laser upgrading projects. With the hope that the use of laser equipment units sufficient technical exchanges, technical services, the key parts of laser equipment for technological transformation. On the one hand, can dramatically enhance the laser output power (1.5 to 2 times) and operating stability, enhance conventional laser hardening and laser cladding processing business productivity on the other hand, can increase the output of low-efficiency and give full play to Power cross-flow CO2 laser processing potential of the domestic help expand the laser processing units laser processing areas, such as laser welding.2 市场调查分析目前，通过对国内千瓦级大功率CO2激光热处理和激光熔覆设备的用户进行调查，很多用户反映设备性能较差，大部分情况为：设备稳定性很差，年故障次数5次以上；激光器使用一至两年后出现功率输出变小、模式变差，因此造成大部分成套设备经常处于低性能状态，甚至停运。主要问题集中在激光器的关键技术指标达不到标准。2 Survey of the marketAt present, through the domestic kilowatt-class high-power CO2 laser heat treatment equipment and laser cladding of the user survey, many users reflect the poor performance of equipment, the majority of cases are: stability of poor equipment, five times the number of failures in more than the use of lasers One to two years after the power output smaller model deteriorate, resulting in complete sets of equipment most often in the low performance, or even outages. Laser focus on key issues in the key indicators-standard technology.千瓦级大功率CO2激光器存在的主要问题及描述序号主要问题简单描述1激光功率“大打折扣”，影响加工效率激光器无法在额定功率下稳定运行，最高功率只能在额定功率的60%下运行（如5000W横流CO2激光器可以稳定运行的功率仅为3000W），也有显示的功率数偏高的现象；如5000W横流CO2激光器功率计显示输出功率为5000W，按计量局标准的手持功率检测仪器显示仅为3000W。因此，很多高功率设备处于低功率运行状态，加工效率降约为标准的一半。2低阶模状态性能差，无法开展新业务（激光焊接、激光切割）根据行业技术标准的规范，合格的横流CO2激光器可以获得多模和低阶模两种激光束模式，低阶模状态的功率为多模的1/2。目前国内的大部分横流CO2激光器通过加“光栅”取得低阶模状态，只能获得多模功率的1/3左右；按照上面多模激光输出功率情况，以5000W的横流CO2激光器为例，在低阶模稳定运行状态下，只获得1000W左右（按技术标准可获得低阶模2500W）。因此，大部分已投入生产的横流CO2激光器的仅采用多模光束，几乎没有开发低阶模及环形模的激光焊接应用技术。3激光器稳定性差设备运行过程中，经常出现光路偏差、电路故障等问题，影响生产进度。经过调查分析，激光器的谐振腔稳定性差，容易出现光轴漂移，引起光斑能量分布不均和激光束偏离外光路中心；电源采用电路板控制，稳定性差；放电系统产生的增益区小。4工艺装备差对于复杂的熔覆工艺，大部分激光设备客户采用重力送粉机构，进行铺粉或预置粉末的办法；无法对复杂形状的零部件进行三维送粉和修复。1kw-class high-power CO2 laser and the main problems describedNo.Main issuesBrief1Laser power greatly reduced, the impact on processing efficiencyLasers can not be rated power under the stable operation of power only in the highest rated power of running under 60 percent (5000 W cross-flow CO2 laser can only stable operation of power 3000 W), also shows that the number of high-power phenomenon such as the 5000 W cross-flow CO2 laser power meter showed that output of 5000 W, measured by the standard hand-held power detection equipment showed that only 3000 W. Therefore, many high-power equipment in a low-power operation, and processing efficiency drop of about half the standard.2Poor performance of low-status, unable to carry out new operations (laser welding, laser cutting)According to industry technical standard specifications, qualified cross-flow CO2 laser can be multi-mode and low-end two-mode laser beam, low-power status for the multi-mode 1 / 2. Most of the current domestic CO2 laser through the cross-flow increases, grating a low-status, multi-mode power can only be 1 / 3 of around accordance with the above multi-mode laser output power, to 5000 W of the cross-flow CO2 laser as an example, in Low-end module and stable operation of state, received only about 1000 W (at the technical standards available to low-end module 2500 W). Therefore, most have been put into production in the cross-flow CO2 laser beam only a multi-mode, almost no development of low-end module and the ring-laser welding applications.3Laser poor stabilityIn the course of operation of equipment, often light path deviation circuit fault and other issues affecting the progress of production. After an investigation of the laser resonator stability of poor, vulnerable to the optical axis drift, caused spots and uneven distribution of energy laser beam from the optical center; power use circuit board control, stability poor discharge system to produce a small gain.4Poor technical equipmentThe complexity of the cladding technology, laser equipment, most of the feeding by gravity, a shop powder or preferences powder; unable to complex 3-D shape of the feeding parts and repair.3 项目实施内容序号升级部位升级项目技术及功能特点描述1激光器光腔光腔采用“高可靠模块化”结构光腔模块结构包括：位置调整模块、角度调整模块、前腔模块、后腔模块、光轴监测模块。光腔调整简单、可操作性强；降低光腔维护成本。2光腔采用“二折高效复合腔”机构 该复合腔在不改变原光腔长度的前提下，增加腔内谐振范围，放电增益区进行充分的激光振荡，电光转换效率达到18%以上。二折腔机构相当于光腔的长度增加一倍，考虑到放电增益区宽度限制，一般可实现额定功率增加1.5倍。3激光器电源、电气控制部分控制系统采用工控机控制。采用工控机作为激光器控制中心，对电流、气压、水流均采用高可靠性传感器件，将采集到的信号输入到工控机中，经程序运算后，输出到相应控制继电器或输出相应模拟量，同时对输出信号进行反馈检测保证程序顺利进行，保证整个控制系统具有高的稳定性及可靠性。4放电极采用多排针放电结构采用多排放电针放电结构，可以实现3排针或更多排放电结构，增大增益区宽度；每个放电针均进行微调处理，使放电系统更稳定。5风机电机驱动变频控制风机电机驱动采用变频控制器，通过改变频率来获得不同的电机转速，实现风机由慢到快的平稳提速过程，同时可以通过工控机实现风机转速的优化调整。适当的提高频率，可增大风机的转速，获得更高的激光输出功率。3 Contents Of Project ImplementationNo.Upgrading siteUpgrade projectsTechnical and functional characteristics described1Laser cavityCavity of highly reliable modular structureCavity module structure, including: position adjustment module, angle adjustment module, the former chamber module, after the chamber module, optical axis monitoring module. Cavity adjustments simple and easy to operate; lower cavity maintenance costs.2Cavity of The presentation of complex cavity efficient body The cavity in the compound does not change the length of the cavity under the premise of increased cavity resonance of the district gain full discharge of laser oscillation, electro-optical conversion efficiency of 18 percent or more. The presentation of chamber body cavity equivalent to double the length, taking into account the discharge gain Width restrictions, can achieve an increase of 1.5 times the rated power.3Laser Power, the electric control part ofControl system uses IPC control.IPC used as a laser control centre, the current, pressure, flow sensors are used pieces of high-reliability, the signal will be collected into the IPC, the operator procedures, corresponding to control output or output relay corresponding simulation Volume, while the output signal detection feedback to ensure a smooth process to ensure that the entire control system with high stability and reliability.4Discharge is a multi-needle discharge structureA multi-emissions electric discharge structure, can achieve three or more emissions-ranked power structure, increasing gain zone width; discharge needles are each fine-tune treatment, the discharge system more stable.5Fan motor drive inverter controlFans used frequency motor drive controller, by changing the frequency of different motor speed, and fans from slow to fast speed of a smooth process, but also through the IPC to achieve optimal adjustment of the fan speed. The improvement of appropriate frequency, can increase the fan speed, the higher the laser power output.4 项目实施技术指标本升级改造项目的立项宗旨为：技术指标达到国内行业标准，部分技术指标超过行业标准。（关于大功率横流连续波CO2激光器的技术标准，请来电索取）以国内现行5KW激光器为例，实施升级改造后的技术性能指标：激光器光腔部分：备注横模模式TEMmnm+n1多模额定输出激光功率（P）W40007500高于行业标准（行业标准多模为5000W）额定输出激光功率连续运行时间（t）h24行业标准额定输出激光功率稳定度%2行业标准光束指向稳定度mrad 0.15行业标准束散角（全角）mrad 2.05行业标准光束传输因子（K） 0.350.07行业标准激光器电光转换效率% 918高于行业标准（行业标准为16%）激光波长 m10.6电源、电气控制部分放电电流不稳定度 %2行业标准电子元器件年故障率 次/年0.5（现行业状况约为5）高于行业标准放电针结构多排针结构， 3高于行业标准电源、电气控制模式工控机（现行业状况为集成电路控制）高于行业标准4 Project Implementation SpecificationsThe upgrading project for the purpose of the project: technical indicators have reached the domestic industry standards, some technical indicators more than the industry standard. (On cross-flow continuous wave high-power CO2 laser, the technical standards, calls for)5 KW to the existing domestic laser as an example, the implementation of upgrading the technical performance indicators:Laser cavity:备注Cross-mode TEMmnm+n1Cross-mode TEMmnRated output laser power (P) W40007500Higher than