Fronius LaserHybrid SB 360i Operating Instructions Manual Download Page 82

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Operation Recommendations for LaserHybrid Weld-

ing System

Recommenda-
tions for the
Operation of a
LaserHybrid
Welding System

For smooth operation, the following items should always be available when using a
LaserHybrid welding system:

LaserHybrid service station

Compressed-air gun supplied with 6 bar

Mobile tool trolley with the following tools and spare parts:
-

20 x contact tips, for each diameter

10 x gas distributors

4 x gas nozzles

One drive roller set incl. compression lever with axles

Allen key set

Side cutter

Release spray

Optics cleaning set from the respective optics manufacturer

1 x protective glass tray, packed to be dust-proof (as reserve)

Min. 10 x protective glasses, packed to be dust-proof

IMPORTANT!

Always have a reserve laser welding head incl. optics in stock!

Delivery time for a new laser welding head:

Delivery time for laser optics:

Repair of laser optics:

min. 8 weeks!
min. 8 weeks!
min. 8 weeks!

IMPORTANT!

Throughout all servicing on the laser welding head, the external extraction

system must be switched on.

Specifications for
the compressed
air supply

To ensure proper functioning, the following specifications for the compressed air supply
must be met:
-

Compressed air supply constant at min. 5 bar

Compressed air free of oil

Compressed air free of water

Compressed air free of dust – no contaminants larger than 5 µm

Summary of Contents for LaserHybrid SB 360i

Page 1: ...e paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy WF 25i LaserHybrid FW WF 60i LaserHybrid FW CMT SB 360i LaserHybrid EN US Operating instructions LaserHybrid 42 0426 0306 EA 007 16032021 ...

Page 2: ......

Page 3: ...Calibrating Power Sources 13 The CE label 13 Copyright 13 General information 15 General 17 General 17 Intended use 17 Applications 17 Laser welding head versions 18 Applications 19 Scope of supply 20 Optional Components 21 Requirements 22 Mechanical Requirements 22 Robot Requirements 22 Ground Connection 22 Alignment 23 System Overview 24 System overview 24 Other LaserHybrid systems 26 Design ver...

Page 4: ...ta Drive conventional 67 Installing Hosepack on Robot 69 Placing the hosepack on the robot 69 Adapting the Additional Extraction System 71 Safety 71 Adapting the Additional Extraction System 71 Threading the Wire Electrode 72 Threading the wire electrode 72 Setting the Contact Pressure on the WF 25i Robacta Drive 72 Setting the contact pressure on the WF 60i Robacta Drive CMT 73 Setting up Laser W...

Page 5: ...ation to the Laser Focus 93 Example Use of the Reference Program after Welding Torch Replacement 94 Measures to Reduce Contamination of the Optics 95 Measures to Reduce Contamination of the Optics 95 Appendix 97 Technical data 99 WF 25i LaserHybrid 90 10 kW FW Laser Welding Head 99 LaserHybrid hosepack MHP 360i LH 99 SB 360i LH 99 WF 25i Robacta Drive W 100 WF 60i Robacta Drive W CMT 100 MTB 700 L...

Page 6: ...ration of the LaserHybrid head All persons involved in the commissioning operation maintenance and servicing of the LaserHybrid head must be suitably qualified have knowledge of welding and have read and implemented carefully these Operating Instructions and the OI for the following system components Laser Laser optics Power source and associated wirefeeder Robot and its controller The Operating I...

Page 7: ...proper use Temperature range of the ambient air During operation 10 C to 40 C 14 F to 104 F During transport and storage 25 C to 55 C 13 F to 131 F Relative humidity Up to 50 at 40 C 104 F Up to 90 at 20 C 68 F Ambient air free of dust acids corrosive gases or substances etc Altitude above sea level up to 2000 m 6561 ft 8 16 in Obligations of the Operating Com pany The operating company must only ...

Page 8: ...walls or install protective curtains Danger from Toxic Gases and Vapors The fumes produced during welding contain toxic gases and vapors Welding fumes contain substances that may cause birth defects and cancer in some cir cumstances Keep your head out of the welding fumes and gases Take the following precautionary measures for fumes and harmful gases Do not breathe them in Extract them from the wo...

Page 9: ...ed Residues pose a risk of explosion Danger from Welding Current An electric shock can be fatal Every electric shock poses a risk of death All welding power leads must be secured undamaged and insulated Replace loose connections and scorched cables immediately Stray Welding Currents If the following instructions are not observed stray welding currents may occur which can result in the destruction ...

Page 10: ...ight or highly reflective reflected laser scattering radiation poses a further risk Take suitable precautions so that persons present have adequate protection from laser scattering radiation also Keep hands hair loose clothing and tools away from moving parts such as Ventilators Gear wheels Rollers Shafts Wirespools and welding wires Do not insert body parts into rotating gear wheels on the wire d...

Page 11: ...n connection with the device or its components must be checked regularly e g for mechanical damage corrosion or changes due to other environmental influences The test interval and scope must as a minimum comply with the respective valid national standards and guidelines There is a risk of colorless odorless shielding gas escaping without notice if an adapter is used for the shielding gas connectio...

Page 12: ...ead if all protective and safety devices are fully func tional If the safety devices are not fully functional there is a risk of injury or death to the operator or a third party damage to the device and other material assets belonging to the operating com pany inefficient operation of the device Safety devices that are not fully functional must be repaired before the device is switched on Never by...

Page 13: ...calibration of power sources is required in accordance with international stand ards The manufacturer recommends a calibration interval of 12 months Please contact your service center if you require further details The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and Electro magnetic Compatibility Directives and therefore has CE sign Copyright Copyright of these Op...

Page 14: ...14 ...

Page 15: ...General information 15 ...

Page 16: ...16 ...

Page 17: ...ng service life of wearing parts Flexible use of the welding system High gap tolerance Adaptation for fiber disk and diode laser possible Intended use The laser welding heads are intended exclusively for automated MIG MAG welding in combination with Fronius system components Any other use does not constitute proper use The manufacturer shall not be held liable for any loss resulting from improper ...

Page 18: ...essibility and space constraints 1 Version 1 Drive unit on the left with central robot support and 2 mounting brackets 2 Version 2 Drive unit on the right with central robot support and 2 mounting brackets 3 Version 3 Drive unit on the left with extension right hand robot support and one mounting bracket 18 ...

Page 19: ...lication Applications Laser welding head version 1 2 1 2 PB PB Example 1 Two sided simultaneous fillet weld PB welding position Angle of contact of the laser approx 80 The position of the wire electrode to the laser is defined by the laser welding head for fillet welds PB welding position for ribs in shipbuilding required for lap joints in crane construction 19 EN US ...

Page 20: ...position for butt welds Scope of supply 1 laser welding head 1 LaserHybrid hosepack MHP 360i LH W FSC FW with external wirefeeding hose 1 drive unit 1 torch body 1 optical adjustment gauge 1 metal gauge to set the focal point 1 extractor tool for register pins 1 combination wrench 10 mm 1 open end wrench 10 mm 1 wrench 8x10 1 bit 1 4 with handle and flexible shaft 1 bit 1 4 840 4 Z 1 TX20 Torx scr...

Page 21: ... ponents The following components are optionally available for the laser welding head Seam tracking system e g secured at the front on the welding head Process monitoring to increase the weld seam quality e g connected to the laser optics Focus monitoring 21 EN US ...

Page 22: ... deviation Robot Require ments The laser welding head weighs around 19 kg The optics weigh a further 3 kg approxim ately A total weight of around 30 kg should be expected for the complete laser welding head when fitted with optics and hosepack It must therefore be possible for the robot axles to move a weight of 30 kg safely with the accelerations specified IMPORTANT The maximum permitted accelera...

Page 23: ...er of serious damage by laser radiation reflected directly into the laser optics This can cause serious damage to the fiber optic Always avoid 90 angles to the work piece surface when aligning the Lase rHybrid head 23 EN US ...

Page 24: ...ingle cooling unit upright console screwed 6 Wirefeeding hose 7 Interconnecting hosepack 8 Robot 9 SplitBox SB 360i LaserHybrid Mounting SB 360i LH 10 LaserHybrid MHP 360i LH W FSC FW hosep ack 11 WF 25i LaserHybrid 90 10 kW FW 12 LaserHybrid cleaning station As an alternative to the welding wire drum a wirespool can also be used for wirefeeding The following components are required for this purpo...

Page 25: ...nsole screwed 6 Wirefeeding hose 7 Interconnecting hosepack 8 Wire buffer 9 Wire buffer control line 10 Robot 11 SplitBox SB 360i LaserHybrid Mounting SB 360i LH 12 LaserHybrid MHP 360i LH W FSC FW hosep ack 13 WF 60i LaserHybrid 90 10 kW FW CMT 14 LaserHybrid cleaning station As an alternative to the welding wire drum a wirespool can also be used for wirefeeding The following components are requi...

Page 26: ...1 Welding wire drum 2 Unwinding wirefeeder WF 25i REEL 4R OPT i WF wire straightener 4 100 880 CK WF MOUNTING Wall 3 Control line for unwinding wirefeeder 4 Remote control 5 TPS 500i power source robot interface CU 1400i Pro MC or CU 2000i MC Single cooling unit upright console screwed 6 Wirefeeding hose 7 Interconnecting hosepack 8 Robot 9 SplitBox SB 360i LaserHybrid wall bracket SB 360i LH 10 L...

Page 27: ... MC Single cooling unit upright console screwed interconnecting hosepack 4 SplitBox SB 360i LaserHybrid OPT i TPS Mount SB 360i LH 5 Wirespool D300 6 Unwinding wirefeeder WF 25i REEL 4R OPT i WF Reel carriage D300 7 LaserHybrid MHP 360i LH W FSC FW hosep ack 8 Wirefeeding hose 9 Robot 10 WF 25i LaserHybrid 90 10 kW FW 11 LaserHybrid cleaning station Support for the SplitBox SB 360i LaserHybrid mou...

Page 28: ...lds on boilers axles etc Power source is in the welding cell II TPS 500i power source HP 95i CON W 1 2 m 95 mm interconnecting hosepack SB 360i LaserHybrid SplitBox mounted on the power source MHP 360i LH W FSC FW 7 5m LaserHybrid hosepack Wirespool WF 25i REEL 4R unwinding wirefeeder WF reel carriage D300 Wirefeeding hose L 10 m Laser welding head Application For test systems only wirespool is no...

Page 29: ...feed movement Example Longitudinal seams on boilers battery trays etc Power source mounted and travels on a gantry TPS 500i power source HP 95i CON W 10 m 95 mm interconnecting hosepack SB 360i LaserHybrid SplitBox mounted on gantry MHP 360i LH W FSC FW 4 2 m or 7 5 m LaserHybrid hosepack Welding wire drum WF 25i REEL 4R unwinding wirefeeder WF MOUNTING Drum Wirefeeding hose L 20 m Laser welding h...

Page 30: ...30 ...

Page 31: ...Operating controls and connections 31 ...

Page 32: ...32 ...

Page 33: ... Robot support central left right depending on configuration 2 Mounting brackets 3 Laser optics 4 Adjustment device 5 Gas nozzle 6 MTB torch body 7 Additional extraction 8 Drive unit WF 25i Robacta Drive WF 60i Robacta Drive CMT 9 Drive unit support 10 MHP robot hose pack 33 EN US ...

Page 34: ...ess and hold the wire return button After pressing the wire return button the wire electrode is retracted by 1 mm 0 039 in After a brief pause the wirefeeder continues retracting the wire electrode if the wire return button is kept pressed down then the speed increases with each further second by 10 m min 393 70 ipm until the preset wire return speed is reached Option 2 Retract the wire electrode ...

Page 35: ...ode meets a ground earth connection then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm 0 039 in Option 2 Thread the wire electrode in 1 mm steps 0 039 in steps always press the wire threading button for less than 1 second tap If the wire electrode meets a ground earth connection then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm 0 039 i...

Page 36: ...necting the coolant return hose from the interconnecting hosepack 7 Welding torch cooling connection coolant supply blue For connecting the coolant supply hose from the interconnecting hosepack 8 SplitBox SB 360i LaserHybrid mount 9 Welding torch connection FSC For connecting the LaserHybrid hosepack 10 Crossjet OUT connection 11 Crossjet OUT connection 12 Crossjet IN connection 13 Interconnecting...

Page 37: ...oling connection return opposite 2 Fiber optic cable for laser Bending radius 200 mm 3 CrossJet extraction connection For connecting a hose as per the following data inner diameter Di 51 mm outer diameter Do 57 mm max length 10 m 4 CrossJet supply For connecting a hose as per the following data 37 EN US ...

Page 38: ... External wirefeeding hose Fronius 7 Radial air supply For connecting a hose as per the following data outer diameter Do 6 mm Compressed air diagram MHP LH LaserHybrid hosepack WF 25i LaserHybrid 90 10 kW FW SB 360i LaserHybrid MHP LH 1 2 3 4 5 6 7 8 5 4 6 9 7 8 7 4 Item Name 1 Compressed air supply line 2 Solenoid valve 3 Internal pressure measurement 4 Pressure measurement option 5 Radial air fl...

Page 39: ...r than 2 seconds then the Powersource Ready bit is withdrawn and the warning code 16835 laser Crossjet air pressure supply low is output From power source software version 2 4 0 If the pressure drops below 4 5 bar for longer than 2 seconds the Warning Bit is set and the error code 16835 laser Crossjet air pressure supply low is output The current Crossjet pressure is displayed in the SmartManager ...

Page 40: ...40 ...

Page 41: ...Commissioning 41 ...

Page 42: ...42 ...

Page 43: ...k Any electrically conductive dust e g from grinding work must not be allowed to be sucked directly into the system Grid Connection The device is designed for the grid voltage listed on the rating plate The fuse protection required for the grid lead can be found in the Technical Data section If mains cables or mains plugs are not included with your version of the appliance attach the appropriate m...

Page 44: ... Connect laser optics and additional extraction system 17 Equip welding torch 18 Place LaserHybrid hosepack on the robot 19 Thread the wire electrode Other activities before start up 20 Adjust the laser welding head 21 Create a reference program 22 Signal sequence for LaserHybrid welding 23 Measures before start of welding 24 Establish ground earth connection between workpiece and power source Set...

Page 45: ...e robot 12 Mount and Connect SplitBox SB 360i LaserHybrid 13 Connect unwinding wirefeeder and wire buffer by means of control line 14 Connect CrossJet 15 Connect the LaserHybrid hosepack to the laser welding head 16 Connect the wirefeeding hose to the wire buffer and the laser welding head 17 Install wirefeed rollers 18 Connect laser optics and additional extraction system 19 Equip welding torch 2...

Page 46: ...e Robot Connection options on the robot The following connection options apply to all laser welding head versions 90 mm 238 mm Example Laser welding head version 1 Drive unit on the left with central robot support and 2 mounting brack ets 46 ...

Page 47: ...m Tightening torque 10 Nm Mounting the Laser Welding Head on the Robot NOTE The laser welding head does not have any collision protection fitted as standard Fronius therefore recommends the use of a commercially available collision protection solution for robotic applications in order to prevent damage to the laser welding head in the event of a crash 1 1 Mount the laser welding head to the robot ...

Page 48: ...Box mount 2 Depending on the robot mount an appropriate support for the SplitBox mount on the robot IMPORTANT Observe robot manufacturer s mounting instructions 3 3 3 3 3 Mount SplitBox mount on the support using 4 Allen screws size 6 mm Tightening torque 24 Nm 4 4 Insert strain relief device of the inter connecting hosepack into the opening and push forwards 48 ...

Page 49: ...clamps x2 7 Insert interconnecting hosepack into the clamps 8 8 8 Close clamps 9 10 10 10 10 10 10 9 Insert SplitBox SB 360i LaserHybrid into the SplitBox mount as per the dia gram 10 Secure SplitBox into the SplitBox mount using 3 TX25 screws from above and 3 TX25 from below Tightening torque 3 5 Nm 49 EN US ...

Page 50: ...g supply line blue d Protective gas shield e SpeedNet from interconnecting hosepack f SpeedNet remote control Gas purging connection 3 2 4 2 Connect LaserHybrid hosepack to welding torch connection FSC 3 Close clamping lever 4 Open cover on LaserHybrid hosepack 6 5 5 Connect connecting plug for welding torch cooling to the LaserHybrid hosepack 6 Connect crossjet air inlet 50 ...

Page 51: ...n nuts size 24 mm Tightening torque 50 Nm IMPORTANT Use flat spanner size 22 mm to hold the items in place when fixing the hexagon nuts in place on the connec tion 9 9 9 9 9 Connect hoses for optics cooling push in Blue marking coolant supply line 10 Connecting Interconnecting Hosepack to Power Source Option 1 1 Data line 3 x 0 5 mm e g for analyzing additional pres sure monitoring 51 EN US ...

Page 52: ... Depending on the robot movement determine the required length of the air hoses and cut the air hoses accordingly to size 5 Withdraw protective hose IMPORTANT When connecting the CrossJet air outlet hoses ensure that the cutting rings are present 6 Connect CrossJet air outlet 7 Secure hose to the connection using a hexagonal nut 24 mm Tightening torque 50 Nm IMPORTANT When securing the hexagon nut...

Page 53: ...8 8 9 Pull protective hoses over the connec tions 53 EN US ...

Page 54: ... Only mount the drive unit when the power source is switched off CAUTION Risk of damage due to dirty or wet coupling points When removing or attaching the hosepack ensure that the coupling point is clean and dry Remove any coolant that has escaped from the coupling point 1 2 42 0411 1315 45 0200 1261 3 11 Nm 8 11 lb ft 4 54 ...

Page 55: ...ing hose 3 6 5 4 3 Press the green locking button and hold it 4 Push the wirefeeding hose into the drive unit until the tension on the lock ing button is released 5 Let go of the locking button 6 Push the wirefeeding hose onwards until the lock engages and the locking button pops out Removal 1 Press the locking button and hold it 2 Pull the wirefeeding hose from the drive unit 55 EN US ...

Page 56: ...g Wirefeed Rollers Inserting repla cing the WF 25i Robacta drive feed rollers 1 2 1 2 0 mm If the roller mount is opened as far as it will go with slight resistance the roller mount will stay in this pos ition 3 4 5 6 56 ...

Page 57: ...7 8 Torx 40 1 Nm 0 74 lb ft 9 10 2 1 11 12 57 EN US ...

Page 58: ...a cing the WF 60i Robacta Drive CMT drive feed rollers 1 2 1 2 0 mm If the roller mount is opened as far as it will go with slight resistance the roller mount will stay in this pos ition 3 4 5 12 mm 42 0411 0160 6 58 ...

Page 59: ...7 8 12 mm 5 Nm 3 69 lb ft 42 0411 0160 2 9 10 2 1 11 12 59 EN US ...

Page 60: ...structions from the manufacturer of the laser optics Before connecting position the laser welding head so that the longitudinal axis of the laser welding head is outside of the horizontal 90 This will ensure that no dirt can get into the laser optics from above 1 1 5x 1 1 1 1 Remove the 5 Allen screws size 6 mm For installation the 3 shorter screws are one below the other the 2 longer screws are o...

Page 61: ... is outside the horizontal 90 4 5 4 Clean connection area using com pressed air 5 Remove the protective cover from the fiber optic cable connection 7 6 6 Clean connector of the fiber optic cable using compressed air 7 Remove the protective cover from the fiber optic cable connector 61 EN US ...

Page 62: ... con nector INCORRECTLY positioned rubber sleeve The rubber sleeve does not seal fully 9 Check whether the rubber sleeve is cleanly sealed all around the fiber optic cable connector IMPORTANT The picture opposite shows an incorrectly positioned rubber sleeve The rubber sleeve shown has a kink in the area indicated by the arrows and therefore it is not fully sealed 10 10 10 Connect the optics cooli...

Page 63: ...upply blue marking 12 12 12 12 Connect the optics cooling return 13 Position the laser welding head in the vertical line Connecting the additional extrac tion system 2 1 1 Push hose over the connection 2 Secure hose with hose clamp 63 EN US ...

Page 64: ...nder the top hole of the mounting bracket 5 5 5 Use a short Allen screw 6 mm to lightly fix the slot nut and mounting bracket 6 7 7 8 6 Insert register pins x2 7 Fit and screw on extractor tool for register pins 8 Knock the striking weight of the extractor tool forward in order to posi tion the register pins 64 ...

Page 65: ...n the 3 shorter screws are one below the other the 2 longer screws are opposite 9 Insert the remaining 4 Allen screws size 6 mm 10 Fix the mounting bracket in place using 5 Allen screws size 6 mm Tightening torque 24 Nm 65 EN US ...

Page 66: ...Preparing Welding Torch Fitting the inner liner in the torch body Plastic inner liner 1 2 3 Steel inner liner 1 2 66 ...

Page 67: ...e WF Robacta Drive conven tional IMPORTANT When removing or attaching the welding torch ensure that the coupling point is clean and dry Remove any coolant that has escaped from the coupling point 1 42 0411 1315 45 0200 1261 2 3 67 EN US ...

Page 68: ...68 ...

Page 69: ...ot arm 2 Mounting HP LH xx Mounting plate depending on robot 3 Item profile 10 50 x 50 mm 2 m 42 1000 0112 4 Optional extension arm 44 0350 0254 4a Mounting plate for CMT wire buf fer 45 1200 0247 5 Opening for extraction hose 6 Opening for wirefeeding hose 7 Opening for fiber optic cable 8 Opening for LaserHybrid hosep ack 9 Adapter insert for extraction hose kit diameter 41 51 mm 42 0411 9036 10...

Page 70: ...top slot on the profile 10 50 x 50 mm 3 7 Tighten the 2 Allen screws size 6 mm 13 and secure the lower sheet metal part 10 with the slot nut 11 to the profile 10 50 x 50 mm 3 Tightening torque 27 Nm 8 Repeat steps 4 7 for all LaserHybrid hosepack holders 9 Using the Allen screw size 3 mm 12 attach the components of the LaserHybrid hosepack holder s back onto the lower sheet metal part 10 Tightenin...

Page 71: ...action system can be adapted to the existing available space NOTE The additional extraction system is factory set for the LaserHybrid welding pro cess Every change in position of the additional extraction system can affect the extraction per formance 2 2 4x 1 1 1 1 1 Loosen 4 Allen screws size 2 5 mm NOTE When adapting the position of the addi tional extraction system ensure that the gas shield re...

Page 72: ...es available in the laser welding head 1 2 1 2 3 1 Press the wire threading button until the wire elec trode comes out of the welding torch 4 Setting the Con tact Pressure on the WF 25i Robacta Drive NOTE Set the contact pressure so that the wire electrode is not deformed but correct wire transport is guaranteed IMPORTANT If the contact pressure is changed significantly the system must be calib ra...

Page 73: ...pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding IMPORTANT If the contact pressure is changed significantly the system must be calib rated The process for calibrating the system is explained in the OI of the power source Contact pressure standard values for steel rollers Al AlSi 1 2 AlMg 2 4 FCW 3 5 CuSi 5 7 Steel 6 8 CrNi 6 8 73 EN US ...

Page 74: ...cs Observe the specifications on the laser optics 1 Welding torch 2 Contact tip 3 Stick out Adjustable axes The spatial position of the arc process to the laser beam can be adjusted in all three Cartesian coordinate axes CAUTION Risk of damage to the optical fiber due to the laser beam being vertical to the workpiece surface If the laser beam is at 90 to the workpiece surface then the laser beam i...

Page 75: ...llen screw 5 mm turn corresponds to an adjust ment path of 0 25 mm 3 Scale for the z axis 4 Adjustment screw with graduation for the x axis Adjustment range 5 mm Allen screw 5 mm turn corresponds to an adjustment path of 0 25 mm 5 Scale for the x axis 6 Adjustment screw with graduation for the z axis Adjustment range 5 mm Allen screw 5 mm turn corresponds to an adjustment path of 0 25 mm Adjusting...

Page 76: ...e adjustment screw 3 Allen key size 5 mm turn corresponds to 0 25 mm 3 After adjusting the y axis re tighten the threaded pin on the adjustment device Adjusting the z Axis 1 3 2 2 1 Loosen threaded pin on the adjust ment device size 2 5 mm 2 Adjust z axis by turning the adjustment screw Allen key size 5 mm turn corresponds to 0 25 mm 3 After adjusting the z axis re tighten the threaded pin on the ...

Page 77: ...m The scope of supply for the laser welding head includes a metal gauge for the exact adjustment of the wire electrode position with respect to the laser focus This gauge is mounted in the working area of the robot and is used to create a reference program for the series components Create a reference program before welding the first series component Requirement The laser welding head must be set u...

Page 78: ... the laser focus Standard value r 4 mm with a stick out of 20 mm and in accordance with the focal length indic ated on the laser optics 7 Document the distance of the wire electrode to the laser focus in the x and y axis in accordance with the scaling on the gauge 8 Save the settings in the robot as the reference program 9 Carry out a test weld The best welding result is used as the basis for the ...

Page 79: ... in direct succession only switch off the CrossJet flow and external extraction system at the end of the entire process This will avoid contamination of the protective glass due to welding fumes Signal Sequence for LaserHybrid Welding Robot start position 1 Set signal Extraction on 2 Set signal Crossjet on NOTE The VALVE ON signal for controlling the solenoid valve in the SplitBox SB 360i LaserHyb...

Page 80: ...ignal Laser on 4 Set signal Start robot LaserHybrid welding end position 1 Stop robot movement 2 Reset signal Laser on 3 Reset signal Welding on 4 Wait until the current flow signal zero Robot end position IMPORTANT The robot end position is not the end of the weld seam 1 Reset signal Crossjet on 2 Reset signal Extraction on 80 ...

Page 81: ...m 2 Check the coolant flow on the welding torch cooling system visual inspection in the coolant tank of the cooling unit 3 Check whether a protective glass is present in the laser optics 4 Check whether all covers are correctly mounted on the laser welding head 5 Test CrossJet 6 Test extraction 7 Test shielding gas 81 EN US ...

Page 82: ...ective optics manufacturer 1 x protective glass tray packed to be dust proof as reserve Min 10 x protective glasses packed to be dust proof IMPORTANT Always have a reserve laser welding head incl optics in stock Delivery time for a new laser welding head Delivery time for laser optics Repair of laser optics min 8 weeks min 8 weeks min 8 weeks IMPORTANT Throughout all servicing on the laser welding...

Page 83: ...Maintenance 83 ...

Page 84: ...84 ...

Page 85: ...ts Safety CAUTION Risk of burns due to the intensely heated welding torch during operation The welding torch may only be cleaned and its components checked once it has cooled down Mounting Wear ing Parts on the Welding Torch 4 5 1 2 3 6 7 8 6x 2x 2x 85 EN US ...

Page 86: ...ing the spatter guard plate 1 1 1 1 2 1 Remove 4 Allen screws size 2 5 mm 2 Replace the spatter guard plate Assemble in reverse order Replacing the Additional Extraction Sys tem 2 2 4x 1 1 1 1 1 Loosen 4 Allen screws size 2 5 mm 2 Replace the extraction system 86 ...

Page 87: ...emoval position the laser optics in front of the laser welding head so that the longitudinal axis of the laser welding head is outside of the horizontal 90 This will ensure that no dirt can get into the laser optics from above NOTE For better accessibility before the laser optics unit is removed the mounting bracket can be removed The following steps are shown when the mounting bracket is removed ...

Page 88: ...ber optic cable from the laser optics is carried out in the reverse order to connection see page 60 from work step 4 Clean fiber optic cable and con nection area with compressed air Withdraw the rubber sleeve in the direction of the optics Press the button on the underside Remove the fiber optic cable Apply the protective covers to the connector of the fiber optic cable and to the fiber optic cabl...

Page 89: ...ics unit can be damaged to such an extent that it is rendered unusable Remove and handle the laser optics carefully 5 4 4 5 Remove the Allen screws M5 x 20 mm size 4 mm The screws are needed again when the new laser optics unit is installed 6 Remove laser optics from the laser welding head Installing the laser optics CAUTION If dropped the laser optics unit can be damaged to such an extent that it...

Page 90: ...ent gauge onto the laser optics so that the register pins engage in the holes for the register pins on the laser optics 2 Secure the optical adjustment gauge with 2 Allen screws M5 x 16 mm size 4 mm 5 5 3 3 3 4 4 On both mounting brackets 3 Loosen 3 Allen screws size 6 mm 4 Remove the 2 register pins 5 If necessary move the profile until the laser optics unit with the mounted optical adjustment ga...

Page 91: ...th the existing 2 Allen screws M5 x 20 mm size 4 mm Do not use the screws M5 x 16 mm out of the scope of supply of the laser optics 10 Position the 2 Allen screws M5 x 20 mm and tighten them size 4 mm Tightening torque 5 7 Nm CAUTION Risk of damage to the laser optics due to stresses Incorrect assembly can cause that stresses that result in the failure of the laser optics The sequence of the follo...

Page 92: ...ster pins on both mounting brackets 18 Tighten the screws on both mounting brackets Tightening torque 24 Nm 19 Check the position of the laser focus using the reference program Final Tasks 1 Connect up all connection sockets on the laser optics according to the OI of the laser optics manufacturer Fiber optic cable Cooling hoses Air hose for radial air flow 92 ...

Page 93: ...placed Each time the laser optics are replaced Each time the welding torch is changed Checking Posi tion of the Wire Electrode in rela tion to the Laser Focus 1 Switch off MIG MAG power source 2 Replace components 3 Switch on MIG MAG power source r 1 1 4 Using the robot move to the reference point on the gauge 1 the laser focus is in the cross hair on the gauge 5 Thread in wire electrode up to the...

Page 94: ...oad the reference program and slowly approach the reference position on the adjustment gauge 6 Thread in wire electrode until this touches the adjustment gauge 7 Check the position of the wire electrode to the laser focus 8 Only if the position is incorrect correct the x y z axis position on the mechanical setting devices of the laser welding head NOT on the robot IMPORTANT Do not under any circum...

Page 95: ...best as you can IMPORTANT Do not blast the protective glass with the air current directly 5 Switch off crossjet 5 Replace protective glass IMPORTANT When replacing the protective glass the extraction must be switched on and crossjet switched off 6 Keep the amount of time the protective glass drawer is open to the minimum neces sary 7 If there are welding fumes on the protective glass replace the p...

Page 96: ...Optic Cable 11 The laser welding head must be in a horizontal position when you are changing the fiber optic cable so that no dust can fall into the optics from above IMPORTANT Clean with compressed air before changing 96 ...

Page 97: ...Appendix 97 ...

Page 98: ...98 ...

Page 99: ... length 4 2 m 7 5 m Lowest cooling capacity as per IEC 60974 2 depending on the hosepack length 1400 1500 W Coolant pressure min max 3 0 5 0 bar Minimum flow of coolant 1 0 l min This product meets the requirements set out in standard IEC 60974 7 10 Cl A SB 360i LH Supply voltage 24 V DC 60 V DC Nominal current 0 5 A 0 8 A Welding current at 10 min 40 C 104 F 40 D C 500 A 60 D C 450 A 100 D C 360 ...

Page 100: ...l current 3 Wire speed 1 25 m min 39 37 984 25 ipm D C duty cycle WF 60i Robacta Drive W CMT X Imax 10 min 40 C M21 EN 439 100 D C 500 A standard 100 D C 280 A CMT X Imax 10 min 40 C C1 EN 439 100 D C 500 A standard 100 D C 280 A CMT Ø mm in 0 8 1 6 032 063 Qmin l min gal min 1 0 26 pmin bar psi 3 43 pmax bar psi 5 72 Supply voltage 60 V DC Nominal current 1 5 A RMS Wire speed 1 60 m min 39 37 236...

Page 101: ...D C 700 A X Imax 10 min 40 C C1 EN 439 100 D C 700 A Ø mm in 1 0 1 6 0 039 0 063 D C duty cycle MTB 500i LH W X Imax 10 min 40 C M21 EN 439 100 D C 500 A X Imax 10 min 40 C C1 EN 439 100 D C 500 A Ø mm in 1 0 1 6 0 039 0 063 D C duty cycle 101 EN US ...

Page 102: ...102 ...

Page 103: ...103 EN US ...

Page 104: ...S INTERNATIONAL GMBH Froniusstraße 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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