Treinamento Fibra

Service Training LF100+LF200
Competence in Laser Marking

Training for operation Maintenance and Service of ALLPRINT CO2-Laser Systems for the Laser Serie
LF100 / LF200 VJ7210 / VJ7310
ALLTEC Laser Business Unit 10.04.2008
Page 1

Introduction Fibre-Laser System
Page 2
Material Effects
Colour Change - Plastics With low laser intensity, a pure warmingup of the marking zone occurs, e.g. thermal cracking of pigments in a plastic with subsequent local colour change. Surface material removal and reveal of a different-coloured base material.
Paint Removal - Paper - Glass etc.
Material Removal (Engraving) - Metal - Glass etc. - Plastics

Increasing the laser intensity causes local evaporation of the surface material with trench formation. The material is engraved.
Page 3
Markings I
Labels/paper
Effect: Paint removal CO2-Laser
Page 4
Markings II
Electronic components
Effect: Colour change CO2-Laser Nd:YAG-Laser Fibre Laser
Page 5
Markings III
Electronic components
Effect: Colour change CO2-Laser Nd:YAG-Laser Fibre Laser
Page 6
Markings IV
Glass
Effect: Material removal in glass (engraving) CO2-Laser
Page 7
Markings V
Metal
Effect: Material removal in metal (engraving) Nd:YAG-Laser

ALLTEC Laser Business Unit 10.04.2008 Page 8
Comparison
White Light - Laser Light
1. Monochromaticity
- The laser emits radiation with only one fixed wavelength.
2. Coherence
- All amplitudes are running in phase.
3. Directionality
- All amplitudes are not divergent, they are nearly parallel. Because of this they can be well focussed.
Page 9
Effect of the Laser Radiation on the Eye

conjunctiva cornea
lens
retina
laser beam
blind spot
optic nerve Laser radiation in the invisible spectrum (e.g. CO2 laser) Laser radiation in the visible spectrum, e.g. HeNe-laser (650nm) or near the visible spectrum, e.g. fibre laser (1070nm) and Nd:YAG-laser (1064nm)
Laser Safety I
Where are the dangers of the ALLPRINT CO2 Laser Marking System?
Invisible laser beam Focused laser beam with very high energy densities Poisonous gas and dust particles are produced during the marking process Reflections (at opened beam delivery system) Danger of fire- and explosion
Page 11
Laser Safety II
The laser beam might cause severe burns of the eyes and the skin as well as damages to objects! That means in the worst case: Loss of the eyesight!
Page 12
Laser Safety III

Never forget when working at the open laser and/or the open beam delivery system: Wear appropriate laser safety goggles!
Indication of suitable laser safety goggles:
DI 1050-1400
L7
LV
DIN CE DIN CE Check Character Manufacturer (here: Laser Vision) Protection Level L7 Range of Wavelength: 1050 nm to 1400 nm * Continous- and Puls Operation
Page 13
Kinds of Damages
Skin damages Normally curable Eye damages Normally incurable
The kind and the coverage of damages depends on the wavelength, the laser power and the exposure to radiation.
Page 14
Units of the Electromagnetic Spectrum

Visible Spectrum
Wavelength in meter(m)
Expression
Gamma Rays
Frequency In Hertz (Hz)
10-12 10-10 10-9

to
1021 1018 1016 1013 1011 1010 108 105
X-Ray
400 nm 700 nm
10-6 10-6
to
Ultraviolet Radiation (UV) Infrared Radiation (IR) Millimeter Waves
10-3 10-3
Nd:YAG 1064 nm
10-2 100 103
Centimeter Waves (Microwaves) Meter Waves (FM Radio + Television) Kilometer Waves (AM Radio)
CO2: 10600 nm
Page 15
Technology
Solid-state lasers
Solid-State Lasers
Use a solid as activating/ lasing medium (as opposed to gas like in CO2 lasers)
Nd:YAG Lasers
Generally use a laser rod Relatively inefficient pumping Water-cooling required
lamp/ diode laser end mirror output coupler
Fiber Lasers
Use a specially doped optical fiber Compact, stable, high beam quality, highly efficient pumping Air-cooling sufficient
Lasing medium: fiber laser Laser beam
aperture
Nd:YAG rod Q-switch
Laser diode + Coupling optic
Mirror
Source: A. Tnnermann, H. Zellmer, H. Welling, "Faserlaser" in Physikalische Bltter, November 1996
Page 16
Technology
Fiber lasers: generals
Scheme of an end pumped fiber laser: Lasing medium: fiber laser
Laser beam
Laser Diode Coupling optic
Mirror
Page 17
The Fibre
The core of the fibre is Ytterbium doped and has a diameter of 10 m.
pump core
refraction index
laser core
Page 18
The Laser Source 1
LF100: YLP-C-1/100/10/10 LF200: YLP-C-1/100/20/20
The Fibre Laser is operated in pulsed operation mode. The following values can be reached:
Page 19
The Laser Source 2

- Datasheet
Parameters IPG name Wavelength Mode of operation Pulse repitition rate Nominal average output power Output power adjustment range Beam quality, M2 (typical) Current consumption Supply voltage Environment temperature range Humidity Warm up time (max.) Cooling method A V C % s kHz W % nm Unit LF100 YLP-C-1/100/10/10 1055-1070 pulsed 20-80 9.5-11 10-100 1.5 5 23-25 0-40 10-95 10 4 build in fans LF200 YLP-C-1/100/20/20 1055-1070 pulsed 20-80 19-21 10-100 1.5 6 23-25 0-40 10-95 10 4 build in fans
Page 20
Function Principle
of a vector scanning laser system
Page 21
Excitation of Atoms
Three important processes in activation of atoms:
1.) Absorption
3.) stimulated Emission 2.) spontaneous Emission
Page 22
Light Amplification (Avalanche Effect)
The first photon to start the avalanche, comes from the laser diode in the beam source.
molecule
photon
Page 23
Definition of the X- and Y- Axis
Page 24
Working Distances and Marking Fields

for SHF60A
Page 25
Working Distances and Marking Fields

for SHF100A
Page 26
Focusing of the Laser Beam

-Diameter of the focus pointlaser beam
Focal length F
dL
dF
Laser scan lens

F = Focal length (in mm) I (YAG) = 100 x I (CO2)
dL = Diameter of the Laserbeam before the lens (in mm) dF = Diameter of the beam in the focus (in mm) B I = Wavelength (in nm) = Modefactor, B(TEM00)=1 = Intensity (in W/mm2) dF (CO2) = 10 x dF (YAG)
dF =
4 F B dL
Page 27
Structure of the Expansion Module

(Telescope) I
Beam direction
Expansion lens
- negative focal length F= -44mm - concave / flat
Collimating lens
- positive focal length F= 90mm - flat / convex
Page 28
Structure of the Expansion Module

(Telescope) II
Standard Expansion Module for SHF- 100A:
Beam Expansion Factor 2.0
Adjustment screw
Collimating lens Expansion lens
Page 29
Assembly of the Beam Expansion (v=2.0)

Standard Expansion Module for SHF- 100A:
Beam Expansion Factor 2.0
Expansion lens
Collimating lens
Page 30
Focusing of the Laser Beam

-Depth of fielddepth of field
2 dF
dF laser beam
2 dF
dF: Diameter of the laser beam at the focus point
Definition: The depth of field is the area, where the diameter of the laser beam, is smaller than twice the focal diameter. Knowledge:
The bigger the beam expansion factor is, the smaller the laser beam can be focussed. The bigger the beam expansion factor is, the bigger is the depth of field. The bigger the focal length is, the bigger is the depth of field.
Page 31
Definition
L A S E R
Light
Amplification by
Stimulated
Emission of
Radiation
Page 32

Software Training Smart Graph 6.x
Page 33
Administration of Markingsystems 1
Page 34
Administration of Markingsystems 2
Page 35
Creating Templates
Template
Contents:
- Text - Numbers - Date/time - Serial numbers - Logos - Lines - Geometrical objects - Barcodes - ID Matrix codes
Parameter Set
Contents:
- Marking intensity - Marking speed - Jump speed - Pulse frequency - Delays - cw-operation
ProductRegistration
Contents:
- Mark on the fly - Marking angle - Encoder operation - Light barrier, slope - Start distance - Triggering - Blockings
Page 36
Arrangement:
- Positioning (X-,Y-coordinates) - Rotation, mirroring,.. - Text options (scaling, ringmarking)
File-Menue
PC-database (on the PC) Function buttons
Online-database (on the laser)
Page 37
The Laser-Operation-Dialogue
- Marking
System state
Informations about the current template
Page 38
- Marking adjustment
Select a template leads to an instant change of the current template Programs for the ext. template selection and for an ext. control of all templates used in the customer database. Rotation and positioning of the current template
Preview of the current template
Zoom tools
Page 39
- Messages
Display of error messages and warnings!!!
Page 40
Creating Templates 1
- The template editor
Page 41
- The main tool-bar
Page 42
- Assignment of parameter set and prod. registration
In the SmartGraph you can generate templates. One parameter set and one product registration, have to be assigned to the new template. What is to be marked?
Select and edit the parameter set and the product registration.
Page 43
- The tool bar list
Select Tool polygon ellipse, circle, arc rectangle text/date/time/SN/shift logo bar code Id matrix code
Page 44
Parameter Set Dialogue

How shall the laser mark? - Which marking intensity (power)? - Which frequency? - Which mirror-and laser delays?
Page 45
Product Registration Dialogue

When shall the laser start marking? (on moved or non-moved products) - With or without product movement? - With automtic consecutive trigger? - With light barrier detection (positive oder negative slope)? - With fixed line speed or incremental encoder operation?
Page 46
Marking Head Dialogue

Which kind of laser components do you use? - Which kind of objective is mounted in your system? - Size of the galvanometers mirrors? - Mounting position of the laser head? - Do you use a tube? - Size of the marking field?
Page 47
System Setting Dialogue

Important software settings - Which IP-address has got my system? - Which system language is desired? - Date and time settings - Shall the pilot laser be active? Power Change Delay:
(is not needed for CO2-Lasers) - System state: Prepare for marking - Standard value: 0 s
Standby Delay:
- System state: Standby - Standard value: 600 s
Page 48

Application-Training
Page 49
Jumps and Strokes
2. Stroke
Ju mp
p m Ju
Jump
Pulsed Stroke (magnified)

Lines with and without Crossings
Lines with crossings
Side view
Lines without crossings
Side view
Page 51
Laserparameter Marking Intensity The laserparameter marking intensity affects extremely the quality of the marking. It alters the power of the laser markingsystem. The marking intensity is adjustable from 0 to 100 %.
Page 52
Laserparameter - Pulse Frequency The pulse frequency is adjustable from 20-80 kHz If you want to increase the pulse frequency, it is only possible to do this in a certain range. When the range is exceeded, the max. acceptable value is displayed.
Page 53
Marking Head Parameter - Jump Delay Meaning: Break time after each jump. Settings: standard: 200-300 s (SHF-100A)
minimum: maximum: 0 s 5000 s jump line (marking) vectors stroke jump delay
Jump Delay too short

Vibration of the galvos at the beginning of a vector.
Jump Delay too long

Marking time is prolonged unneccesarily.
Page 54
Laser Parameter - On Delay Meaning: The time between starting of

the galvo mirrors at the beginning of of a stroke and the turn-on of the laser beam. jump line (marking) vectors stroke on delay
Settings: standard: -200 s (negative!)

minimum: -1000 s maximum: 1000 s
On Delay too short

The beam source is turn-on delayed. We need a negative On Delay for fibre lasers.
On Delay too long

The beginnings of the strokes are not marked, because the laser beam is turned-on too late. The galvo mirrors have been moved in the meantime.
Page 55
Marking Head Parameter - Stroke Delay Meaning: Break time at the end
of each stroke. jump line (marking) vectors stroke stroke delay
Settings: standard:
150 s (SHF-100A) minimum: 0 s maximum: 2000 s
Stroke Delay too short

The galvo mirrors get the command, to jump to a new position, before they have reached the end of the stroke.
Stroke Delay too long

Marking time is prolonged unneccesarily.
Page 56
Laser Parameter - Off Delay Meaning: The time between stopping

of the galvo mirrors at the end of a stroke and the turn off of the laser beam. jump line (marking) vectors
Settings: standard:
150 s minimum: 0 s maximum: 1000 s
stroke off delay
Off-Delay too short

The ends of the strokes are not marked, because the laser beam is turned-off too early. The galvo mirrors have not reached their end positions.
Off-Delay too long

At each end of a stroke the laser beam burns into the material, because the laser beam is turned-off too late. The galvo mirrors are already in their end position.
Page 57
Marking Head Parameter - Mark Delay Meaning:

Break time at each minimum vector. jump line (marking) vectors stroke mark delay
Settings: standard:
minimum: maximum:
0 s (SHF-100A) 0 s 999 s
Mark Delay too short

With high marking speed, curves appear at the corners.
Mark Delay too long

Marking time is prolonged unneccesarily. At each end of a vector, the laser beam burns into the material. (Exception: The last vector of a stroke.)
Page 58

System Description
Page 59
System Overview
Interface Unit Supply Unit
Marking Head
Page 60
Data Transmission 1
Page 61
Data Transmission 2
Page 62
Data Transmission 3
Page 63
The Supply Unit 1

L2 L1 L3 S3 G55 S4/S5 S1/S2
S1/S2 Main switch: ON/OFF Starts the booting/shuts down the laser S3 Key-operated switch: Applies the laser power for the beam source 0 = Laser is not ready to mark 1 = Laser is ready to mark
L1
L2 L3
Laser is ready to mark or marking. The key-operated switch is in position ON, laser radiation can be released. Blinking: Error Blinking: System is booting Normal white: System is booted Bright white: System is marking
S4/S5 Start/Stop switch: Starts and stops the marking process.

G55 Socket of the Handheld

Page 64
The Supply Unit 2

24V/320W-Power-supply: - By connecting mains the power supply is powered up (fan in the power supply is running). - When the ON button is pressed, the relay on the interface board, connects the power supply to the interface board (system boots up).
FM Fan ACC-3 24V FLEB+
Marking head cable Interface board Mains cable
FibreLaser source
Ethernet-connection Serial Interface RS232

Fibrecable
Cablegland
Customer interface
Page 65
The Marking Head (Pilot Laser+mirror)
Pilot Laser
Pilot Beam Turning Mirror Mounted on a solenoid Beam shutter Axis
Page 66
The Marking Head (Scanner mirrors)
X-Mirror
Y-Mirror

Hardware Training
Page 68
Hardware Overview
Data and signal processing of the laser system
Page 69
Data and signal processing
Page 70
Technical Data 1
Page 71
Technical Data 2
Page 72
The Interlock Circuit

Under construction
Page 73
System States 1
System OFF
main switch ON
Initialize
main switch OFF and ON again
Fatal Error
Key-switch open
close key- switch
acknowledge
Laser start up
Interlock open
Laser ready Start stop Prepare for marking acknowledge stop
Error
Stand-by
after 10 min.
start Wait for trigger
stop
Marking
stop
Page 74
System States 2
Page 75
Timing-Diagram 1
Page 76
Timing-Diagram 2
Page 77
Timing-Diagram 3
Page 78
The ACC-3
Advanced Controler Card-3 (Index J and higher):
Dip- Switch 1: Sets IP-adress 192.168.1.1 Subnet-Mask:255.255.0.0 DIP-Switch 2: no function
X1: 30 V Power jumper placed : 12V for Customer I/O jumper not placed: 24V for Customer I/O
Page 79
The ACC-3
Function of the LEDs 1 Index F
Page 80
The ACC-3
Page 81
The ACC-3
Page 82
The ACC-3
Page 83
The ACC-3
Page 84
The Backup-Battery
on the ACC-3 board
The battery buffers the following dynamic datas, in the SRAM (128 KB) on the ACC-2 board:
The last used template Dynamic datas for all templates (e.g.: serial numbers, variables, shift codes, etc.) Time and date (the clock even runs if the laser is switched off) Error warnings and messages If the laser is switched off, the lifetime of the battery is approximately 1.5 - 2 years. If the laser is switched on, the lifetime is approximately 3-5 years. That means, the longer the laser is switched on, the longer is the lifetime of the battery. When the battery is empty, an error warning will be generated.
Page 85
The MMC Card Multi Media Card

on the ACC-3 board
On the MMC the following datas are permanently stored:
- Customer database - Component files (laser, markinghead, lens) - Operating system (Linux, AOS) - Processor- and board software (FPGA, FM, ACC-3)
An operating system update, and an update of logics or component files, can be easily done, by exchanging the MMC, when the system is switched off. A renewed booting of the system, happens already with the new software releases.
Page 86
Programming of the MMC
Page 87
The Interface Board

Under construction
- The Interlock circuit is switched on the Interface board. - Voltage converter, generates 24V to -24V.
Page 88
The FM Board
The Fast Move Board (Index M and higher)
Power consumption FM Board : 300 Watt
The FM-board is inside the supply unit. Digital scanners are manufactured by Cambridge Technologies. They are made of silicium and covered with dielectrical layers. On board is an EEPROM, which contains deflection system datas. In case of an error the FM-board has to be exchanged together with both mirrors. The copper cooling plate carries -24V.
The FLEB+
The Faser Laser Extension Board
Under construction
Page 90
The Membrane Board

Under construction
Page 91

The Customer Interface
Page 92

Digital Inputs Connector X20 Incremental Encoder Connector X7 Digital Outputs Supply Voltage for digital I/O 12/24 V Connector X16 Light Barrier/Initiator Connector X6
CAN-Bus Connector X14
Interlock Circuit Connector X2
Under construction
Page 93

Under construction
Page 94

Under construction
Page 95
Standard Connection to Lightbarrier and Encoder
Page 96
The external customer interface

for ext. template selection via CAN-BUS and PLC
Data 0-7 plus ext. event

Timing Diagram 4
- External template selection
Page 98
Calculation of the max. available

Marking time for single line marking
Product movement 200 mm = 0,2 m Example: Vproduct = 9 km/h = 9 km x 1000 m h 3600 s Vproduct = 2,5 m/s max. availabe marking time: tmax = 0,2 m s = 0,08 s = 80 ms 2,5 m
Length of the marking Length of the marking field EXP: 12.2008
60 mm
140 mm
Page 99
Compensation of the Movement 1

(Mark On The Fly MOTF)
1. Select the template with the current parameter set and the current product registration. The size of the square and the marking time should correspond to the template be marked later on. The marking time can be displayed with the info-button in the template. Dont forget to set the correct laser power. 2. Start the test. When the square opens or closes in line direction, the distance per rotation of the incremental encoder has to be changed, in the field: Distance/Rot.. Square opens in line direction. Remedy/measure: Distance per rotation must be decreased! Square closes in line direction. Remedy/measure: Distance per rotation must be increased!
Product movement
Compensation of the Movement 2

(Mark On The Fly MOTF)
When the square opens or closes in direction of the laser, the angle has to be changed in the field:Angle between laser axis and direction of product movement. Square opens in laser direction. Remedy/Measure: Angle must be increased! Square closes in laser direction. Remedy/Measure: Angle must be decreased!
Product movement
Important: First mark the square without product movement, to make sure that the parameter on-delay is setted correctly!

The Handheld G55
Page 102
The Handheld G55

Shock Proofed Body Lighted Display
with WYSIWYG-view
F1 F2 F3 F4 F5
Funktion Buttons
Alphanumeric Keypad
POE-Port (Power Over Ethernet)
Page 103
The Handheld G55 - User Levels - 1
Page 104
The Handheld G55 - User Levels - 2

Operator
1. Store database 2. Select current template 3. Adjust marking - Set Variables - Rotation - X-Offset - Y-Offset - Laser power
Technician
1. Store database 2. Select current template 3. Adjust marking - Set Variables - Rotation - X-Offset - Y-Offset - Laser power - Marking speed - select current product registration 4. Create new templates, parameter sets and product registrations 5. Modify, delete and copy templates, parameter sets and product registrations 6. System settings - Set time and date
Administrator
1. - 3. Same as in technician level 4. System settings - Set time and date - Change unit of measurement - Change handheld language - Change system language - Change IME (special characters) - Network setup (IP-adresses) - Markinghead adjustment - Pilotlaser adjustment - Change G55 passwords 4. Create new parameter sets and product registrations 5. Modify, delete and copy parameter sets and product registrations
4. View error warnings
7. View alert history
6. View alert history
Page 105
The Handheld G55

- The Keypad
Page 106
The Handheld G55

- used Symbols (via Funktion Buttons) - 1
Page 107
The Handheld G55

- used Symbols (via Funktion Buttons) - 2
Page 108

Maintenance and Inspection
Page 109
The Maintenance Plan

Monthly: Check the laser scan lens for dust and dirt. Clean the laser scan lens incase of dust or stains. Monthly or when control lamp lights up: If installed: Exchange the filter bag inside the exhaust unit (refer to manual the exhaust unit). Every three months (more frequently when oprated in dirty ambient conditions): Carry out a visual inspection of the laser system. Every six months: If installed: Exchange the charcoal filter inside the exhaust unit (refer to manual of the exhaust unit).
Page 110
Cleaning the Laser Scan Lens
Page 111
ALLTEC - Contact
If you need help... ... please contact our Service-Hotline: Tel. +49-(0)38823-55-360 We are available for your support from 06:00 to 18:00 from Monday to Friday! If for any reason it is impossible to connect you directly with our service technician, you are automatically connected to our answer phone. Please provide the following information: your name name of your company your telephone number! the reason for your call
We will return your call a.s.a.p.!
Page 112

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Service Training LF100+LF200

Competence in Laser Marking

LF100 / LF200 VJ7210 / VJ7310

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Competence in Laser Marking

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Paint Removal - Paper - Glass etc.

Material Removal (Engraving) - Metal - Glass etc. - Plastics

Service Training LF100+LF200

Effect: Paint removal CO2-Laser

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Effect: Colour change CO2-Laser Nd:YAG-Laser Fibre Laser

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Effect: Colour change CO2-Laser Nd:YAG-Laser Fibre Laser

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Effect: Material removal in metal (engraving) Nd:YAG-Laser

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Effect of the Laser Radiation on the Eye

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Laser Safety III

Indication of suitable laser safety goggles:

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Units of the Electromagnetic Spectrum

Frequency In Hertz (Hz)

10-12 10-10 10-9

1021 1018 1016 1013 1011 1010 108 105

Ultraviolet Radiation (UV) Infrared Radiation (IR) Millimeter Waves

10-2 100 103

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

Nd:YAG rod Q-switch

Laser diode + Coupling optic

Source: A. Tnnermann, H. Zellmer, H. Welling, "Faserlaser" in Physikalische Bltter, November 1996

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200

The Laser Source 1

LF100: YLP-C-1/100/10/10 LF200: YLP-C-1/100/20/20

ALLTEC Laser Business Unit 10.04.2008

Service Training LF100+LF200