3000w 6000w laser cladding machine

1.System Introduction

Laser cladding equipment can be used for laser cladding processing on the surface of shafts, disks and other parts to increase the hardness or corrosion resistance of the surface. Laser processing has metallurgical bonding, small deformation, low interface dilution material, dense structure, fine grains, and high surface compressive stress fatigue life.

The metal surface is coated using a high-energy laser beam with an energy density of 106 W/m2, which forms a very strong metallurgical bond with the substrate by locally melting the raw material.

Different design

2.Features

●6000w laser source, high quality and stability, continuous operation in 48 hours;

●The quality of laser working lens, high uniformity of spot, good thermal stability, long focal length of lens, small lens pollution, long service life and low damage rate;

● Independent research and development of semiconductor laser control system with high integration, easy operation, space saving and convenient maintenance;

● Six-axis robot control robot slide rail and spindle realize 6+2 axis linkage, high precision machining and wide adaptability;

● Based on Siemens self-developed operation platform based on years of experience, the system integration operation is simple and one-button control, the machine tool adapts to a wide range and the equipment covers a small area;

3.System Configuration

NO.	Name	Model	Supplier	Qty	Remarks
1	Laser source	6000W	Everfoton	1	Raycus,MAX
2	Laser cladding head	Cladding spot 4.2mm	Questt	1
3	Powder feeder	double cylinders	Questt	1
4	Robot	1650mm robot arm	Domestic	1	6+2 axis system
5	Dust purification system	SLE-550FP	Questt	1
6	Central control system	PLC+touch screen	Questt	1	PLC controller
7	Water chiller	Dual temperature	Hanli China	1	6000w
8	Two-axis positioners	Customized	Questt		Payload 300kg

4. Specifications

4.1 Laser source 

The fiber laser dedicated to cladding has the characteristics of high electro-optical efficiency, multiple anti-high reflection, compact structure, and convenient system integration. It can provide a maximum core diameter of 1000μm output, flat-top distribution of spot energy, higher powder utilization rate and better molding effect during the cladding process.

Optical Properties
Output Laser Power (W)	6000
Work model	Continuous/modulation
Polarization direction	random
Power adjust range (%)	10~100
Beam quality (nm)	30
Modulation frequency (Hz)	50~5kHz
Red light output power (mW)	QBH
Beam Diffusion Half（rad）	≤0.22
Fiber cable length (m)(m)	20
Fiber Core diameter (μm)	600
Electrical characteristics
Voltage	Three-phase five-wire 380V±10%,50/60Hz
Control method	RS-232/AD
Other characteristics
Dimension(W×H×D)	600×750×600
Working temperature (℃)	10~40
Working humidity (%)	＜70
Storage temperature (℃)	-10~60
Cooling system	Water cooled

4.2 Laser cladding head 

The laser head can be loaded with 6000W laser power, and the basic configuration includes: QBH fiber interface, collimator module, focus module, shifting powder, protected mirror module, etc., by air curtain protection lens is not splash and smoke contamination .

1） Send powder of the powder head is the coaxial powder, and the front end has coaxial blow protection, that is, protects the surface of the cladding to prevent oxidation, and prevent splashing powder particles from entering the molten head to avoid protective glasses. Pollution. Sending pink is modular design, only need to replace the corresponding parts when the damage is occurs, the operation is convenient, and the cost is low.

2) The laser processing head is equipped with a protective lens mount (using a drawer design) to facilitate replacement and cleaning of the lens: the entire processing head seal, prevent dust and other particulate debris from entering the optical path system, effectively protecting optical lenses, extending service life .

3) Cooling method: water is cold, guaranteed working in large area, long working stability during work.

4) The laser processing head is made of transmission lens, and the lens protection is used, and the laser output spot is performed, the spot is uniform, the thermal stability is good, the lens is contaminated, the lens is long, and the damage rate is low.

Optical Head Data Sheet ：

4.3 Powder feeder 

Double-cylinder powder feeder is a double-cylinder powder feeder that relies on a powder feeding tray to measure the quantity and transports powder with carrier gas. The repeatability of the double-cylinder powder feeding is ±2%, and it can transport various thermal spray powders with particle sizes of 20~220μm. The rotation speed range of the powder feeding plate is 0~2 rpm, and the powder feeding amount is continuously adjustable. The powder feeder can be used as a component of the laser cladding equipment, and the barrel position can be used alone or at the same time.

4.4 Robot arm

BRTIRUS1820A is a six-axis robot developed by BORUNTE for complex applications with multiple degrees of freedom. The maximum load is 20kg, the maximum arm length is 1850mm. Lightweight arm design, compact and simple mechanical structure, in the state of high speed movement, can be carried out in a small workspace flexible work, meet the needs of flexible production. It has six degrees of flexibility.Suitable for loading and unloading, injection machine, die casting, assembling, coating industry, polishing, detection etc.It is suitable for injection molding machine range from 500T-1300T. The protection grade reaches IP54 at the wrist and IP40 at the body. The repeat positioning accuracy is ±0.05mm.

MainSpecification

Arm Length(mm)：1850

Repeatability(mm)：±0.05

Loading Ability(kg)：20

Power Source(kVA)：5.87

Weight(kg)：230

4.5 Dust purification system

Smoke purification system has the advantages of large air volume, stability and reliability, small footprint, simple structure, economy and practicality, and can achieve non-toxic and tasteless discharge in situ. Suitable for all kinds of laser marking processing, meet the special working conditions of general clean production requirements, can directly absorb all kinds of smoke, odor, dust generated by laser processing and purification, discharge harmless air.

4.6 Central Control System

This system uses PLC as the main control unit, integrating lasers, robots, powder feeders, man-machine interfaces, etc.

The central control system integrates the relevant information of the robot and the laser, which can control the start and stop of the robot, the start and stop of the laser, the power of the laser, and the start and stop of the powder feeder. After the robot processing program is written, after setting the laser power on the central control system, the processing can be completed with one button.

4.7 Water chiller

It adopts a dual-temperature chiller with two water circulations including the main circuit and the external optical path. The low-temperature water of the main circuit is used to cool the laser, and the normal temperature water of the external optical circuit is used to cool the lens and optical fiber connectors. Satisfied with the use of 6000 W fiber-coupled semiconductor laser, it has automatic fault diagnosis function.

4.8 Two-axis positioners

1, the fuselage surface sandblasting,plastic spraying,antirust processing.

2.Welding, tempering and precision machining of fuselage structure.

3.The tailstock through hole can pass through the cable.

4. Copper-based carbon brush with brush collection in tailstock

5.Reservation button is standard.

6. Anchor adjusting component(optional)

7. Controller (optional)

8. Please consult our company for special requirements of positioner.

9. The positioner supports customization of other specifications.

Specifications

5. Samples