大功率横流CO2激光器升级改造项目

1、大功率横流CQ激光器升级改造项目Power Cross-Flow CO 2 Laser Upgrading Projects1 项目概要通过对国大功率横流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CO激光器的加工潜力，帮助国各激光加工单位拓展激光加工领域，如激光

2、焊接。1 . IntroductionThrough the cross-flow of domestic high-power CO2laser units use the investigationandtechnical analysis, the combined company in the cross-flow CO2 laser's technical superiority, I decided to con duct some on-li ne laser upgradi ng projects.With the hope that the use of laser

3、equipme nt un its sufficie nt tech ni cal excha nges,tech ni cal services, the key parts of laser equipme nt for tech no logicaltra nsformatio n.On the one hand, can dramatically enhance the laser output power (1.5 to 2 times) andoperatingstability, enhance conventional laser hardening and laser cla

4、dding processingbus in ess productivityon the other hand, can in creasethe output of low-efficie ncy andgive full play to Power cross-flow CO2 laser processing potential of the domestic helpexpa nd the laser process ing un its laser process ing areas, such as laser weld ing.2 .市场调查分析目前，通过对国千瓦级大功率CO2

5、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 prese nt, through the domestic kilowatt-class high-power CO2 laser heat treatme ntequipment and laser cladding of the user survey, many users r

6、eflect the poor performaneeof equipment, the majority of cases are: stability of poor equipment, five times thenumber of failures in more than the use of lasers One to two years after the power output smaller model deteriorate, result ing in complete sets of equipme nt most often in the low performa

7、 nee, or eve n outages. Laser focus on key issues in the key in dicators-sta ndard tech no logy.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4II> II!ii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iIII|I率的60%下运行（如5000W横流CO2激光器可以稳定运行的功率|> i；激光功率“大打折 |仅为3000V）也有显示的功率数偏高的现象；如5000W横流CO2II1 扣”，影响加工效率:激光器功率计显示输出功率为5000W按计量局标准的手持功

8、率> i:丨丨检测仪器显示仅为 3000Wi I-III 因此，很多高功率设备处于低功率运行状态，加工效率降约I ij丨为标准的一半。I| 根据行业技术标准的规，合格的横流CO2激光器可以获得多|4jjji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。|:I:HII低阶模状态性能I目前国的大部分横流 CO2激光器通过加“光栅”取得低阶模iII差，无法开展新业 |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llII2务（激光焊接、激|率情况，以5000W的横流CO2激光器为例，在低阶模稳定运行状j光切割）|态下，只获得1000W左右（按技术标准可获得低阶模2500

9、V）|HII:I:因此，大部分已投入生产的横流 CO2激光器的仅采用多模光3IIII束，几乎没有开发低阶模及环形模的激光焊接应用技术。IaII|i 设备运行过程中，经常出现光路偏差、电路故障等问题，影i-I-III响生产进度。:J2 激光器稳定性差|经过调查分析，激光器的谐振腔稳定性差， 容易出现光轴漂:I'HIIi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II Ii丨I电路板控制，稳定性差；放电系统产生的增益区小。III II-S.厶厶.|1 0 U4!：亠亠厶 ST厶丿H »： iiZ H厶厶厶 4S亠!£.厶厶H il-S 厶 a I厶4B 11

10、4亠 4E 0厶厶4Bn Z厶JII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III3 工艺装备差I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> i；I三维送粉和修复。1kw-class high-power CO2 laser and the main problems describedBriefMain issuesNo.Laser power "greatly reduced", the-1 impact on process ingiefficie ncy:Lasers can not be rated power under the

11、 stable operation of:power only in the highest rated power of running under 60: a.:percent (5000 Wcross-flow CO2laser can only stable operationj of power 3000 W), also shows that the number of high-power;phenomenon such as the 5000 Wcross-flow CO2laser power metershowed that output of 5000 W, measur

12、ed by the standard:hand-heldpower detectionequipment showed that only 3000 W.!:Therefore, many high-power equipment in a low-power- i operation, and processing efficiency drop of about half the；standard.Poor performa nee of low-status,:un able to carry out new2operati ons (laser:weldi ng, laser cutt

13、 in g):According to industry technical standard specifications,ii qualified cross-flow CO2laser can be multi-mode and low-endI:two-mode laser beam, low-power status for the multi-mode 1 !/ 2.；Most of thecurrent domestic CO2laser through the cross-flowI "grat ing" a low-status, multi-mode p

14、ower can onlyIaround accordanee with the above multi-mode laserLaser poor3 stabilityPoor tech nical4equipme nti in creases,i be 1 / 3 ofij output power, to 5000 W of the cross-flow CO2 laser as ani example, in Low-end module and stable operation of state,received only about 1000 W (at the technical

15、standardsi available to low-end module 2500 W).i;Therefore, most have been put into production in thecross-flow CO2 laser beam only a multi-mode, almost noi development of low-end module and the ring-laser welding:applications.m n resk m n ": w in: rr s-b re in: w reBi: w s-i In the course of o

16、peration of equipment, often light pathdeviation circuit fault and other issues affecting the:progress of production.:After an in vestigati on of the laser res on ator stability of:poor, vulnerable to the optical axis drift, caused spots and;uneven distribution of energy laser beam from the opticali

17、 center; power use circuit board control, stability poor:discharge system to produce a small gain.i n a| n n a-a !- va in n ! tb an av a-a bis 0I The complexity of the claddi ng tech no logy, laser equipme nt,i:most of the feeding by gravity, a shop powder or preferences1i powder; unable to complex

18、3-D shape of the feeding parts andIi repair.3项目实施容序号升级部位升级项目技术及功能特点描述光腔采用“高光腔模块结构包括：位置调整模块、角度调整模块、可靠模块化”前腔模块、后腔模块、光轴监测模块。结构光腔调整简单、可操作性强；降低光腔维护成本。激光器光腔该复合腔在不改变原光腔长度的前提下,增加腔谐光腔采用“二振围，放电增益区进行充分的激光振荡,电光转换效率折高效复合 达到18%以上。腔”机构二折腔机构相当于光腔的长度增加一倍,考虑到放1.5 倍。电增益区宽度限制，一般可实现额定功率增加* an n n aa am an i采用工控机作为激光器控制中

19、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控制系统采用工控机中，经程序运算后，输出到相应控制继电器或输工控机控制。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。激光器电源、4电气控制部分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。.a aa a a a A-b a a 亠 has s a亠 a as a a = B a a 亠 has kb aa-风机电机驱动采用变频控制器，通过改变频率来获风机电机驱动变频控制得不同的电

20、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。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 Implementationi Upgradingi Upgradei Technical and functional characteristics describedNo.siteprojectsNo.Upgradi ngsiteUpgrade projectsTechnical and functional characteristics described:11Cavity of "hig

21、hly reliable modular" structureCavity module structure, in clud ing: positi on1adjustme nt module, an gle adjustme nt module, theformer chamber module, after the chamber module,! optical axis mon itor ing module.1Cavity adjustmentssimple and easy to operate; lower1 cavity maintenance costs.2Las

22、er cavityCavity of "The prese ntati on of complex cavityefficie nt" bodyThe cavity in the compou nd does not cha nge the'Ilen gth of the cavity un der the premise of i ncreasedcavityresonance of the districtgain full dischargeof laseroscillati on,electro-opticalcon versi on1 efficie nc

23、y of 18 perce nt or more.The prese ntati on of chamber body cavity equivale nt1 to double thelen gth,tak ingintoaccou nt the1 discharge gain Width restricti ons, can achieve anin crease of 1.5 times the rated power.3rLaser Power, the electric con trol part ofCo ntrolsystem usesIPC con trol.IPC used

24、as a laser con trol cen tre, the curre nt,!pressure, flow sen sors are used pieces ofhigh-reliability, the signal will be collected intothe IPC, the operator procedures, corresp onding tocon trol output or output relay corresp onding1simulationVolume, while the output signal detectionfeedback to en

25、sure a smooth process to en sure thati the en tire con trol system with high stability and1 reliability.4Discharge is a multi-needle discharge structureA multi-emissi onselectric discharge structure,canachieve three or more emissi on s-ra nked power1 structure, in creas ing gain zone width; discharg

26、e-1n eedles are each fin e-tu ne treatme nt, the discharge system more stable.5Fan motor drive in verter con trolFans used freque ncy motor drive con troller, bychanging the frequency of different motor speed, and1 fans from slow to fast speed of a smooth process, but also through the IPC to achieve

27、 optimal adjustme ntof the fan speed. The improveme nt of appropriate1 freque ncy,can in crease the fan speed, the higher the1 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 C02激光器的技术标准，请来电索取）以国现行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TEMmn1m+nc 11i1多模i!额定输出激光功率（P） W

28、!i40001 11 1175001i咼于行业标准（行业标准多 j模为5000W额定输出激光功率连续运行时间（t）h>i24i11i:：行业标准i额定输出激光功率稳定度 %i± 2i1行业标准光束指向稳定度 mrad <0.15行业标准束散角（全角）mrad <2.01i51j1行业标准光束传输因子（K）>1 10.35ii0.07; :行业标准激光器电光转换效率% >|iI；91 1II i；18II 1咼于行业标准1（行业标准为16%）激光波长卩m10.6i _ 电源、电气控制部分i放电电流不稳定度 %| ± 2 |1ri行业标准电子元器件

29、年故障率次/年0.5 （现行业状况约为 5）咼于行业标准放电针结构多排针结构，> 31咼于行业标准电源、电气控制模式工控机（现行业状况为集成电路控制）咼于行业标准4. Project Implementation SpecificationsThe upgrading project for the purpose of the project:technicalindicators have reachedthe domestic in dustry sta ndards, some tech ni cal in dicators more tha n the in dustrysta

30、ndard. (On "cross-flow continuous wave high-power CO2laser,"the technical standards,calls for)4 KW to the exist ing domestic laser as an example, the impleme ntati on ofupgradi ng thetech ni cal performa nee in dicators:Laser cavity:备注Cross-mode TEM mnm+n< 1Cross-mode TEM mnRated output las