大功率橫流CO2激光器升級改造項目

1、 沈陽新松機器人自動化股份有限公司 激光再造及成套裝備中心大功率橫流CO2激光器升級改造項目Power Cross-Flow CO2 Laser Upgrading Projects項目概要通過對國內(nèi)內(nèi)大功率率橫流CCO2激激光器使使用單位位的調(diào)查查和技術(shù)術(shù)分析，結(jié)結(jié)合我公公司在橫橫流COO2激光光器方面面的技術(shù)術(shù)優(yōu)勢，我我公司決決定開展展部分在在線激光光器的升升級改造造項目。希望與各激激光設(shè)備備的使用用單位進進行充分分的技術(shù)術(shù)交流，通通過技術(shù)術(shù)服務(wù)，對對激光設(shè)設(shè)備的關(guān)關(guān)鍵部位位進行技技術(shù)改造造。一方方面，可可大幅提提升激光光器的輸輸出功率率（1.522倍）和和運行穩(wěn)穩(wěn)定性，提提高常規(guī)規(guī)激光淬

2、淬火和激激光熔覆覆加工業(yè)業(yè)務(wù)的生生產(chǎn)效率率；另一一方面，可可提高低低階模的的輸出效效率，充充分發(fā)揮揮大功率率橫流CCO2激光器器的加工工潛力，幫幫助國內(nèi)內(nèi)各激光光加工單單位拓展展激光加加工領(lǐng)域域，如激激光焊接接。IntrooducctioonThrouugh thee crrosss-fllow of dommesttic higgh-ppoweer CCO2 lasser uniits usee thhe iinveestiigattionn annd ttechhniccal anaalyssis, thhe ccombbineed ccomppanyy inn thhe ccrosss-

3、ffloww COO2 llaseerss teechnnicaal ssupeeriooritty, I ddeciidedd too coonduuct somme oon-llinee laaserr uppgraadinng pprojjectts. Witth tthe hoppe tthatt thhe uuse of lasser equuipmmentt unnitss suuffiicieent tecchniicall exxchaangees, tecchniicall seerviicess, tthe keyy paartss off laaserr eqquippm

4、ennt ffor tecchnoologgicaal ttrannsfoormaatioon. On thee onne hhandd, ccan draamatticaallyy ennhannce thee laaserr ouutpuut ppoweer (1.55 too 2 timmes) annd ooperratiing staabillityy, eenhaancee coonveentiionaal llaseer hharddeniing andd laaserr clladddingg prroceessiing bussineess prooducctivvityy

5、onn thhe ootheer hhandd, ccan inccreaase thee ouutpuut oof llow-effficiienccy aand givve ffulll pllay to Powwer crooss-floow CCO2 lasser proocesssinng ppoteentiial of thee doomessticc heelp exppandd thhe llaseer pproccesssingg unnitss laaserr prroceessiing areeas, suuch as lasser welldinng.市場調(diào)查分分析目前

6、，通過過對國內(nèi)內(nèi)千瓦級級大功率率CO22激光熱處處理和激激光熔覆覆設(shè)備的的用戶進進行調(diào)查查，很多多用戶反反映設(shè)備備性能較較差，大部分分情況為為：設(shè)備備穩(wěn)定性性很差，年年故障次次數(shù)5次次以上；激光器器使用一一至兩年年后出現(xiàn)現(xiàn)功率輸輸出變小小、模式式變差，因因此造成成大部分分成套設(shè)備備經(jīng)常處處于低性性能狀態(tài)態(tài)，甚至至停運。主主要問題題集中在在激光器器的關(guān)鍵鍵技術(shù)指指標(biāo)達不不到標(biāo)準(zhǔn)準(zhǔn)。Surveey oof tthe marrkettAt prreseent, thhrouugh thee doomessticc kiilowwattt-cllasss hiigh-powwer CO22 laase

7、rr heeat treeatmmentt eqquippmennt aand lasser claaddiing of thee usser surrveyy, mmanyy usserss reefleect thee pooor perrforrmannce of equuipmmentt, tthe majjoriity of casses aree: sstabbiliity of pooor eequiipmeent, fiive timmes thee nuumbeer oof ffaillurees iin mmoree thhan thee usse oof llaseers

8、 Onee too twwo yyearrs aafteer tthe powwer outtputt smmalller moddel detteriioraate, reesulltinng iin ccompplette ssetss off eqquippmennt mmostt offtenn inn thhe llow perrforrmannce, orr evven outtagees. Lasser foccus on keyy isssuees iin tthe keyy inndiccatoors-staandaard tecchnoologgy.千瓦級大功功率COO2激

9、光光器存在的的主要問題題及描述述序號主要問題簡單描述1激光功率“大打折折扣”，影響響加工效效率激光器無法法在額定定功率下下穩(wěn)定運運行，最最高功率率只能在在額定功功率的660%下下運行（如如50000W橫橫流COO2激光光器可以以穩(wěn)定運運行的功功率僅為為30000W），也也有顯示示的功率率數(shù)偏高高的現(xiàn)象象；如550000W橫流流CO22激光器器功率計計顯示輸輸出功率率為50000WW，按計計量局標(biāo)標(biāo)準(zhǔn)的手手持功率率檢測儀儀器顯示示僅為330000W。因此，很多多高功率率設(shè)備處處于低功功率運行行狀態(tài)，加加工效率率降約為為標(biāo)準(zhǔn)的的一半。2低階模狀態(tài)態(tài)性能差差，無法法開展新新業(yè)務(wù)（激激光焊接接、激光光

10、切割）根據(jù)行業(yè)技技術(shù)標(biāo)準(zhǔn)準(zhǔn)的規(guī)范范，合格格的橫流流CO22激光器器可以獲獲得多模模和低階階模兩種種激光束束模式，低低階模狀狀態(tài)的功功率為多多模的11/2。目前國內(nèi)的的大部分分橫流CCO2激激光器通通過加“光柵”取得低低階模狀狀態(tài)，只只能獲得得多模功功率的11/3左左右；按按照上面面多模激激光輸出出功率情情況，以以50000W的的橫流CCO2激激光器為為例，在在低階模模穩(wěn)定運運行狀態(tài)態(tài)下，只只獲得110000W左右右（按技技術(shù)標(biāo)準(zhǔn)準(zhǔn)可獲得得低階模模25000W）。因此，大部部分已投投入生產(chǎn)產(chǎn)的橫流流CO22激光器器的僅采采用多模模光束，幾幾乎沒有有開發(fā)低低階模及及環(huán)形模模的激光光焊接應(yīng)應(yīng)用技術(shù)術(shù)

11、。3激光器穩(wěn)定定性差設(shè)備運行過過程中，經(jīng)常出現(xiàn)光路偏差、電路故障等問題，影響生產(chǎn)進度。經(jīng)過調(diào)查分分析，激激光器的的諧振腔腔穩(wěn)定性性差，容容易出現(xiàn)現(xiàn)光軸漂漂移，引引起光斑斑能量分分布不均均和激光光束偏離離外光路路中心；電源采采用電路路板控制制，穩(wěn)定定性差；放電系系統(tǒng)產(chǎn)生生的增益益區(qū)小。4工藝裝備差差對于復(fù)雜的的熔覆工工藝，大大部分激激光設(shè)備備客戶采采用重力力送粉機機構(gòu)，進進行鋪粉粉或預(yù)置置粉末的的辦法；無法對對復(fù)雜形形狀的零零部件進進行三維維送粉和和修復(fù)。1kw-cclasss hhighh-poowerr COO2 llaseer aand thee maain proobleems dess

12、criibeddNo.Main isssuessBrieff1Laserr poowerr ggreaatlyy reeducced, tthe imppactt onn prroceessiing effficiienccyLaserrs ccan nott bee raatedd poowerr unnderr thhe sstabble opeerattionn off poowerr onnly in thee hiigheest ratted powwer of runnninng uundeer 660 pperccentt (550000 W crooss-floow CCO2

13、lasser cann onnly staablee opperaatioon oof ppoweer 330000 W), aalsoo shhowss thhat thee nuumbeer oof hhighh-poowerr phhenoomennon succh aas tthe 50000 WW crrosss-fllow CO22 laaserr poowerr meeterr shhoweed tthatt ouutpuut oof 550000 W, meeasuuredd byy thhe sstanndarrd hhandd-heeld powwer dettecttio

14、nn eqquippmennt sshowwed thaat oonlyy 30000 W. Theerefforee, mmanyy hiigh-powwer equuipmmentt inn a loww-poowerr opperaatioon, andd prroceessiing effficiienccy ddropp off abboutt haalf thee sttanddardd.2Poor perrforrmannce of loww-sttatuus, unaablee too caarryy ouut nnew opeerattionns (lasser welldi

15、nng, lasser cutttinng)Accorrdinng tto iinduustrry ttechhniccal staandaard speecifficaatioons, quualiifieed ccrosss-ffloww COO2 llaseer ccan be mullti-modde aand loww-ennd ttwo-modde llaseer bbeamm, llow-powwer staatuss foor tthe mullti-modde 11 / 2. Mosst oof tthe currrennt ddomeestiic CCO2 lasser t

16、hrrouggh tthe crooss-floow iincrreasses, ggrattingg aa loow-sstattus, muultii-moode powwer cann onnly be 1 / 3 of arooundd acccorrdannce witth tthe aboove mullti-modde llaseer ooutpput powwer, too 50000 W oof tthe crooss-floow CCO2 lasser as an exaamplle, in Loww-ennd mmoduule andd sttablle ooperrat

17、iion of staate, reeceiivedd onnly aboout 10000 WW (aat tthe tecchniicall sttanddardds aavaiilabble to loww-ennd mmoduule 25000 WW). Theerefforee, mmostt haave beeen pput intto pprodducttionn inn thhe ccrosss-ffloww COO2 llaseer bbeamm onnly a mmultti-mmodee, aalmoost no devveloopmeent of loww-ennd m

18、moduule andd thhe rringg-laaserr weeldiing apppliccatiionss.3Laserr pooor staabillityyIn thhe ccourrse of opeerattionn off eqquippmennt, oftten ligght patth ddeviiatiion cirrcuiit ffaullt aand othher isssuess afffecctinng tthe proogreess of prooducctioon. Aftter an invvesttigaatioon oof tthe lasser

19、ressonaatorr sttabiilitty oof ppoorr, vvulnneraablee too thhe ooptiicall axxis driift, caauseed sspotts aand uneevenn diistrribuutioon oof eenerrgy lasser beaam ffromm thhe ooptiicall ceenteer; powwer usee ciircuuit boaard conntrool, staabillityy pooor disschaargee syysteem tto pprodducee a smaall g

20、aiin.4Poor tecchniicall eqquippmenntThe ccompplexxityy off thhe ccladddinng ttechhnollogyy, llaseer eequiipmeent, moost of thee feeediing by graavitty, a sshopp poowdeer oor ppreffereencees ppowdder; unnablle tto ccompplexx 3-D sshappe oof tthe feeedinng ppartts aand reppairr.項目實施內(nèi)內(nèi)容序號升級部位升級項目技術(shù)及功能能

21、特點描描述1激光器光腔腔光腔采用“高可靠靠模塊化化”結(jié)構(gòu)光腔模塊結(jié)結(jié)構(gòu)包括括：位置置調(diào)整模模塊、角角度調(diào)整整模塊、前前腔模塊塊、后腔腔模塊、光光軸監(jiān)測測模塊。光腔調(diào)整簡簡單、可可操作性性強；降降低光腔腔維護成成本。2光腔采用“二折高高效復(fù)合合腔”機構(gòu) 該復(fù)復(fù)合腔在在不改變變原光腔腔長度的的前提下下，增加加腔內(nèi)諧諧振范圍圍，放電電增益區(qū)區(qū)進行充充分的激激光振蕩蕩，電光光轉(zhuǎn)換效效率達到到18%以上。二折腔機構(gòu)構(gòu)相當(dāng)于于光腔的的長度增增加一倍倍，考慮慮到放電電增益區(qū)區(qū)寬度限限制，一一般可實實現(xiàn)額定定功率增增加1.5倍。3激光器電源源、電氣氣控制部部分控制系統(tǒng)采采用工控控機控制制。采用工控機機作為激激

22、光器控控制中心心，對電流、氣氣壓、水水流均采采用高可可靠性傳傳感器件件，將采采集到的的信號輸輸入到工工控機中中，經(jīng)程程序運算算后，輸輸出到相相應(yīng)控制制繼電器器或輸出出相應(yīng)模模擬量，同同時對輸輸出信號號進行反反饋檢測測保證程程序順利利進行，保保證整個個控制系系統(tǒng)具有有高的穩(wěn)定性性及可靠靠性。4放電極采用用多排針針放電結(jié)結(jié)構(gòu)采用多排放放電針放放電結(jié)構(gòu)構(gòu)，可以以實現(xiàn)33排針或或更多排排放電結(jié)結(jié)構(gòu)，增增大增益益區(qū)寬度度；每個個放電針針均進行行微調(diào)處處理，使使放電系系統(tǒng)更穩(wěn)穩(wěn)定。5風(fēng)機電機驅(qū)驅(qū)動變頻頻控制風(fēng)機電機驅(qū)驅(qū)動采用用變頻控控制器，通通過改變變頻率來來獲得不不同的電電機轉(zhuǎn)速速，實現(xiàn)現(xiàn)風(fēng)機由由慢到快

23、快的平穩(wěn)穩(wěn)提速過過程，同同時可以以通過工工控機實實現(xiàn)風(fēng)機機轉(zhuǎn)速的的優(yōu)化調(diào)調(diào)整。適適當(dāng)?shù)奶崽岣哳l率率，可增增大風(fēng)機機的轉(zhuǎn)速速，獲得得更高的的激光輸輸出功率率。Conteentss Of Projjectt ImpllemeentaatioonNo.Upgraadinng ssiteeUpgraade proojecctsTechnnicaal aand funnctiionaal ccharractteriistiics desscriibedd1Laserr caavittyCavitty oof higghlyy reeliaablee moodullar sttruccturreCavit

24、ty mmoduule strructturee, iinclludiing: poosittionn addjusstmeent moddulee, aanglle aadjuustmmentt moodulle, thee foormeer cchammberr moodulle, aftter thee chhambber moddulee, ooptiicall axxis monnitoorinng mmoduule. Caavitty aadjuustmmentts ssimpple andd eaasy to opeeratte; lowwer cavvityy maaintte

25、naancee coostss.2Cavitty oof Thee prreseentaatioon oof ccompplexx caavitty eeffiicieent boody Thhe ccaviity in thee coompooundd dooes nott chhangge tthe lenngthh off thhe ccaviity undder thee prremiise of inccreaasedd caavitty rresoonannce of thee diistrrictt gaain fulll ddisccharrge of lasser oscci

26、lllatiion, ellecttro-optticaal cconvverssionn effficcienncy of 18 perrcennt oor mmoree. TThe preesenntattionn off chhambber boddy ccaviity equuivaalennt tto ddoubble thee leengtth, takkingg innto acccounnt tthe disschaargee gaain Widdth resstriictiionss, ccan achhievve aan iincrreasse oof 11.5 timme

27、s thee raatedd poowerr.3Laserr Poowerr, tthe eleectrric conntrool ppartt offContrrol sysstemm usses IPCC coontrrol.IPC uusedd ass a lasser conntrool ccenttre, thhe ccurrrentt, ppresssurre, floow ssenssorss arre uusedd piiecees oof hhighh-reeliaabillityy, tthe siggnall wiill be colllecctedd innto the

28、e IPPC, thee opperaatorr prroceedurres, coorreespoondiing to conntrool ooutpput or outtputt reelayy coorreespoondiing simmulaatioon VVoluume, whhilee thhe ooutpput siggnall deetecctioon ffeeddbacck tto eensuure a ssmoooth proocesss tto eensuure thaat tthe enttiree coontrrol sysstemm wiith higgh ssta

29、bbiliity andd reeliaabillityy.4Dischhargge iis aa muultii-neeedlle ddisccharrge strructtureeA mullti-emiissiionss ellecttricc diischhargge sstruuctuure, caan aachiievee thhreee orr moore emiissiionss-raankeed ppoweer sstruuctuure, inncreeasiing gaiin zzonee wiidthh; ddisccharrge neeedlees aare eacch

30、 ffinee-tuune treeatmmentt, tthe disschaargee syysteem mmoree sttablle.5Fan mmotoor ddrivve iinveerteer cconttrollFans useed ffreqquenncy mottor driive conntroolleer, by chaangiing thee frrequuenccy oof ddifffereent mottor speeed, annd ffanss frrom sloow tto ffastt sppeedd off a smooothh prroceess,

31、buut aalsoo thhrouugh thee IPPC tto aachiievee opptimmal adjjusttmennt oof tthe fann sppeedd. TThe impprovvemeent of appproppriaate freequeencyy, ccan inccreaase thee faan sspeeed, thee hiigheer tthe lasser powwer outtputt.項目實施技技術(shù)指標(biāo)標(biāo)本升級改造造項目的立立項宗旨旨為：技技術(shù)指標(biāo)標(biāo)達到國國內(nèi)行業(yè)業(yè)標(biāo)準(zhǔn)，部部分技術(shù)術(shù)指標(biāo)超超過行業(yè)業(yè)標(biāo)準(zhǔn)。（關(guān)于大功率橫流連續(xù)波CO2激光

32、器的技術(shù)標(biāo)準(zhǔn)，請來電索取）以國內(nèi)現(xiàn)行行5KWW激光器器為例，實施升級改造后的技術(shù)性能指標(biāo)：激光器光腔腔部分：備注橫模模式TTEMmmnm+n11多模額定輸出激激光功率率（P）WW40007500高于行業(yè)標(biāo)標(biāo)準(zhǔn)（行業(yè)標(biāo)準(zhǔn)準(zhǔn)多模為為50000W）額定輸出激激光功率率連續(xù)運運行時間間（t）hh24行業(yè)標(biāo)準(zhǔn)額定輸出激激光功率率穩(wěn)定度度%2行業(yè)標(biāo)準(zhǔn)光束指向穩(wěn)穩(wěn)定度mmradd 0.15行業(yè)標(biāo)準(zhǔn)束散角（全全角）mmradd 2.05行業(yè)標(biāo)準(zhǔn)光束傳輸因因子（KK） 0.350.07行業(yè)標(biāo)準(zhǔn)激光器電光光轉(zhuǎn)換效效率% 918高于行業(yè)標(biāo)標(biāo)準(zhǔn)（行行業(yè)標(biāo)準(zhǔn)準(zhǔn)為166%）激光波長 m10.6電源、電氣氣控制部部分放電電

33、流不不穩(wěn)定度度 %2行業(yè)標(biāo)準(zhǔn)電子元器件件年故障障率 次/年0.5（現(xiàn)現(xiàn)行業(yè)狀狀況約為為5）高于行業(yè)標(biāo)標(biāo)準(zhǔn)放電針結(jié)構(gòu)構(gòu)多排針結(jié)構(gòu)構(gòu)， 3高于行業(yè)標(biāo)標(biāo)準(zhǔn)電源、電氣氣控制模模式工控機（現(xiàn)現(xiàn)行業(yè)狀狀況為集集成電路路控制）高于行業(yè)標(biāo)標(biāo)準(zhǔn)Projeect Impllemeentaatioon SSpeccifiicattionnsThe uupgrradiing proojecct ffor thee puurpoose of thee prrojeect: teechnnicaal iindiicattorss haave reaacheed tthe dommesttic inddusttry sta

34、andaardss, ssomee teechnnicaal iindiicattorss moore thaan tthe inddusttry staandaard. (OOn crooss-floow cconttinuuouss waave higgh-ppoweer CCO2 lasser, tthe tecchniicall sttanddardds, callls forr)5 KW to thee exxisttingg doomessticc laaserr ass ann exxampple, thhe iimpllemeentaatioon oof uupgrradiing thee teechnnicaal pperfformmancce iindiicattorss:Laserr caavitty:備注Crosss-moode TEMMmnm+n11Crosss-moode TEMMmnRatedd ouutpuut llaseer ppoweer (P) W40007500Hi