intelliweld smart welding

Transcription

1 intellield more Information at: smart welding Designed for robot-assisted welding applications, this 3D-scan system is capable of swiftly positioning the laser beam along 3D contours. hile a robot guides the scan system along a part s contour, the intellield quickly and accurately moves and finepositions the laser spot. Complex robotic motions and fast robotic repositioning are thereby avoided, thus reducing positioning times between spot welds to a few milliseconds. The result is a substantially enhanced utilization of the laser source. Despite its 30 mm aperture, the intellield occupies a remarkably small volume, making it easily mountable on welding robots, even in difficult-to-access locations. Its optics are optimized for fiber-coupled disk or fiber lasers with powers up to 8 k. The intellield is based on SCANLAB s fully digital idrive technology, offering an integrated approach to laser and process safety. The technology allows real-time monitoring of all important scan head status parameters. A software-independent interlock signal indicates abnormal operational states. Typical applications: Robot-assisted welding ( remote welding ) 3D applications Processing-on-the-fly

2 intellield 30 FC + intellield 30 FC V Legend Mounting screws * 2 Flange (robot adapter plate) * 3 Alignment pins * 4 Attachment provision for strain relief (fiber) 5 Attachment provision for fiber adapter 6 Connector for cooling water Data interface 8 Interlock 9 Power in 0 Bore holes for attaching an objective holder and a crossjet * not included all dimensions in mm Principle of Operation The laser beam is fiber-delivered to the scan system s water-cooled collimator and then directed to the scan system s moving deflection mirrors. ith pre-objective scanning design, focusing of the beam onto the working plane is achieved via a scan objective at the system s beam exit. ith post-objective scanning design, focusing is achieved via an integrated focusing optic in front of the deflection mirrors (see figures left). The variable collimator s optic is dynamically driven along the optical axis via the linaxis linear axis, thereby altering the collimated laser beam s divergence as well as the overall system s focal length. The scan system is equipped with a sealed housing. Two protective windows serve to protect the scan objective or the beam exit. intellield 30 FC as well as intellield 30 FC V are available with an objective or a prefocusing optic. Process Monitoring 9 Pre-Objective Scanning Post-Objective Scanning All intellield scan systems have connections for process monitoring. Light or radiation emanating from the workpiece and returning via the deflection mirrors is decoupled from the optical path for potential analysis via additional process monitoring equipment. Furthermore, the intellield 30 FC V (the V means vision) is equipped with a second camera port with variable camera-tracking optics. This enables process monitoring with continuously readjusted camera focus in the complete operating volume. 8 8 Legend Fiber adapter 2 Variable collimator 3 Dichroic mirror 4 Focusing optics 5 Galvanometer scanner 6 Galvanometer scanner 2 7 Objective 8 orking plane 9 Attachment provision for process monitoring 20 Variable camera tracking optics ** 2 Camera connection ** ** only for intellield 30 FC V

3 intellield Control The intellield 30 FC incorporates SCANLAB s fully digital idrive technology, offering an integrated approach to laser and process safety. It allows real-time monitoring of all important scan head and double protective window status parameters. This facilitates detection of process miss-queues and enables advanced remotediagnostics. A software-independent interlock signal, indicating abnormal operational states, can be used to switch the system to a predefined state or trigger an automatic emergency stop. Options A Teach-In Module simplifies the setup of laser scan systems for welding jobs. It is permanently installed at the intellield scan system s beam exit side. Two laser diodes project (via deflection mirrors) a large crosshair and a small 45 -offset crosshair onto the workpiece and thereby visualize the position of the working laser beam s focus. Both crosshairs exactly intersect at the working volume s center (x = y = z = 0). This enables a simple and quick optical control during a Teach-In process, whether the scan system of the robot is positioned correctly above a defined welding position. The RobotSyncUnit is a central operating/control unit for laser welding systems (laser, intellield and robot). Simple and intuitive system usage brings efficiency to programming of welding tasks (see also image right). For further information on the RobotSyncUnit, visit the website of Blackbird Robotics: Digitial I/O Fieldbus interface (PROFIBUS, PROFINET, DeviceNet, etc.) Robot RobotSyncUnit. l Import and editing of processing tasks l Teach-in of processing tasks l Interactive projection preview on real workpiece l Assisted cycle time optimization l Various operating modes (setup, production) l Safety controller with secure stop and reset Robot control Superordinate cell controller Configurable communication interface Vision system and/or other peripherals Scan system and laser control via RTC 5 board Laser Remote welding on-the-fly SL2-00 intellield scan system

4 intellield Specifications (all angles are in optical degrees) avelength 030 nm nm () Maximum laser power 8000 (2) (with specified cooling) Characteristics of the collimator Focal length 0 mm Limiting numerical aperture typ (3) Fiber adapter QBH, Q5 / LLK-B, QD / LLK-D (other types on request) Step response time (with "step" tuning) (settling to /000 of full scale) % of full scale.2 ms 0% of full scale 3.5 ms 00% of full scale ms Typical speeds (with "vector" tuning) Processing Speed 4 rad/s Positioning Speed 50 rad/s Dynamic performance Tracking error 0.6 ms Repeatability < 22 µrad Long-term drift over 8 h < 0.6 mrad (after warm-up) Optical performance Typical scan angle ±0.35 rad Gain error < 5 mrad Nonlinearity < 3.5 mrad Power requirements ±(5+.5) V DC, max. 8 A each Input and output signals SL2-00 or optical data transfer (XY2-00-O) eight 2-37 kg Operating temperature 25 C ± 0 C Typical water 3 l/min at 20 C and requirements p < 0. bar, p < 4 bar () mirror coatings for 030 nm, nm and nm are currently available (2) the maximum laser power may be reduced with broadband scan mirrors (3) adapters for smaller numerical apertures are available Typical Optical Configurations Pre-Objective scanning Post-Objective scanning Focal length of focusing optics 460 mm 330 mm 660 mm Free operating distance 488 mm 382 mm 472 mm Image volume size (cuboid-shaped) (220 x 220 x 40) mm 2 (85 x 85 x 80) mm 2 (370 x 370 x 200) mm 2 Image field size (elliptical) (385 x 300) mm 2 (240 x 200) mm 2 approx. (450 x 450) mm 2 Focus range in z direction ±70 mm ±40 mm up to ±00 mm Focus diameter 630 µm (with 50 µm fiber) 600 µm (with 200 µm fiber) 600 µm (with 00 µm fiber) Fiber diameter 00 µm, 50 µm or µm or 200 µm 50 µm or 00 µm µm Image scale :4 :3 :6 2 / 20 Information is subject to change without notice. SCANLAB AG Siemensstr. 2a 8278 Puchheim Germany Tel. +49 (89) Fax +49 (89) info@scanlab.de SCANLAB America, Inc. 00 Illinois St St. Charles, IL 6074 USA Tel. + (630) Fax + (630) info@scanlab-america.com

5 powerscan, powerscan i more Information at: maximum-power laser scanning The scan systems of the powerscan series enable positioning multiple kilowatts of laser power onto a workpiece in just a few milliseconds. In combination with a varioscan, the laser beam can be dynamically focused within working volumes, thus allowing non-flat workpieces to be processed. Apertures from 33 mm up to 70 mm allow small spot sizes and therefore high power densities even with large working distances. The XY mirrors and the varioscan s optics are air cooled, while the scanners, electronics and varioscan are water cooled. This ensures reliable operation with excellent long-term stability even under challenging environmental conditions and with high laser powers. Each axis of the powerscan 50, 50i, 70 and 70i is individually implemented as a sealed submodule a calibrated and tuned unit containing a galvanometer scanner with a mirror and the scanner s drive electronics. Thus, rapid replacement of individual axes is ensured. Located in a separate sealed base module, the modularlydesigned main electronics provide functions such as a digital interface and a power management system with comprehensive monitoring functions. The powerscan i-series of scan systems employs the same idrive electronic concept used in the success-proven intelliscan. This brings improved dynamics and advanced querying possibilities. The series includes both the powerscan 50i and powerscan 70i. Typical applications: Laser processing of materials Rapid manufacturing 3D applications Processing-on-the-fly

6 powerscan 33 E 2 3 Legend Beam in 2 Entrance aperture (water-cooled) 3 varioscan 40 4 Clamping block (water-cooled) 5 Base plate 6 Beam out 7 Galvanometer scanner E Electrical connectors A Connector for cooling air Connectors for cooling water all dimensions in mm Beam exit side 4 5 A 7 Beam entrance side Optics SCANLAB precisely optimizes and tunes all optical components to one another to ensure maximum focus quality and stable process parameters. The powerscan can be equipped with a varioscan for dynamically focusing the laser beam. Numerous optical configurations specially developed for the varioscan and matched to the powerscan are available for various wavelengths, laser powers and image fields or working volumes. Customers can easily self-install these exchangeable varioscan optics sets to adapt the scan system for their applications. Control The powerscan systems can be controlled via a SCANLAB RTC control board. This facilitates straight-forward implementation of applications even complex ones. The RTC board automatically performs all required computations, such as microvectorization and image field correction, and synchronously controls the powerscan, varioscan and laser. Processing-on-the-fly functionality is optionally available. 4 x Ø6.4 4 x M4 2 x Ø6 H Dimensions powerscan 33 Aperture 33 mm Beam displacement 45.2 mm

7 3x Ø6.6 powerscan 50, 50i + powerscan 70, 70i D P A 9 powerscan 50 and powerscan 70 scan systems may be equipped with interfaces for electrical or optical data transfer. powerscan 50i and powerscan 70i systems are controlled via the SL2-00 interface. 8 7 Options powerscan systems can be equipped with an additional reference sensor system for automatic self-calibration for applications requiring extremely high long-term stability powerscan systems can be equipped with sensors for monitoring the cooling air (standard at powerscan 50, 50i, 70 and 70i) Beryllium mirrors are optionally available for maximized dynamic performance (powerscan 33 and 50) powerscan 50i and 70i afford all advantages of the idrive technology: high flexibility, high dynamic and realtime querying of the actual position and other status data 6 5 Legend Beam in 2 Entrance aperture (water-cooled) 3 varioscan 60 4 Clamping block (water-cooled) 5 Base plate 6 Beam out 7, 8 Submodules 9 Base module with main electronics D Fiber connector for optical data transfer P Power supply connector A Connectors for cooling air Connectors for cooling water all dimensions in mm Beam exit side 4 Ø Beam entrance side A x Ø6.6 6H7 6H x M all dimensions in mm The powerscan 70 and 70i have a larger housing (L//H 566mm/360mm/342mm) compared to the pictured powerscan 50 and 50i, but have the same function unit. Dimensions powerscan 50/50i powerscan 70/70i Aperture 50 mm 70 mm Beam displacement mm 98.2 mm

8 powerscan, powerscan i Typical Optical Configurations powerscan 33 with varioscan 40 powerscan 50/50i with varioscan 60/varioSCAN de 60i avelength 0.6 µm 0.6 µm 0.6 µm 0.6 µm 0.6 µm 0.6 µm 0.6 µm Max. laser power cw Max. laser power for 50% duty cycle Image field size (70 x 70) mm 2 (500 x 500) mm 2 (.5 x.5) m 2 (400 x 400) mm 2 (600 x 600) mm 2 (800 x 800) mm 2 (.0 x.0) m 2 Typical processing speed 0.8 m/s 2.0 m/s 6.0 m/s.3 m/s 2.0 m/s 2.7 m/s 3.2 m/s Focus range in z direction ±4 mm ±35 mm ±75 mm ±0 mm ±40 mm ±50 mm ±00 mm Focus diameter (/e 2 ) 20 µm (M 2 =) 450 µm (M 2 =).3 mm (M 2 =) 250 µm (M 2 =) 375 µm (M 2 =) 500 µm (M 2 =) 600 µm (M 2 =) Beam expansion factor Focal length (44 ± 5) mm (850 ± 75) mm (2300 ± 500) mm (750 ± 50) mm (050 ± 90) mm (350 ± 50) mm (650 ± 250) mm powerscan 70/70i with varioscan 80/varioSCAN de 80i avelength 0.6 µm 0.6 µm 0.6 µm Max. laser power cw Max. laser power for 50% duty cycle Type-Dependent Specifications (all angles are in optical degrees) powerscan 33 powerscan 50/50i powerscan 70/70i Aperture 33 mm 50 mm 70 mm Beam displacement 45.2 mm mm 98.2 mm Step response time (settling to /000 of full scale) % of full scale.3 ms.5 ms / 2.0 ms (*) 2.8 ms / 3.5 ms (*) 0% of full scale 4.5 ms Typical processing speed 3 rad/s 2.5 rad/s.5 rad/s Typical positioning speed 8 rad/s 5 rad/s / 25 rad/s (*) 2 rad/s / 5 rad/s (*) Dynamic performance Tracking error 0.75 ms 0.9 ms.6 ms Power requirements ±(5+.5) V DC, max. 4.5 A each Image field size (440 x 440) mm 2 (.0 x.0) m 2 (.6 x.6) m 2 Typical processing speed 0.9 m/s 2.0 m/s 3.2 m/s Focus range in z direction ±0 mm ±75 mm ±200 mm Focus diameter (/e 2 ) 220 µm (M 2 =) 450 µm (M 2 =) 650 µm (M 2 =) Beam expansion factor Focal length (860 ± 45) mm (680 ± 200) mm (2440 ± 400) mm ±(24+.5) V DC, max. 0 A each (20 A peak current) ±(24+.5) V DC, max. 0 A each (20 A peak current) eight 2 kg 33 kg 35 kg (with varioscan) Typical air requirements clean, filtered air clean, filtered air clean, filtered air >.5 bar.5 bar to 2.0 bar.5 bar to 2.0 bar (*) the higher value applies to the powerscan i Common Specifications (all angles are in optical degrees) Dynamic performance Repeatability Long-term drift over 8 hours (after warm-up) Optical performance Typical scan angle Gain error Zero offset Skew Nonlinearity Input signals Analog version (not powerscan i) Digital version powerscan powerscan i Ouput signals Analog version (not powerscan i) Digital version powerscan < 22 µrad < 0.6 mrad ±0.35 rad < 5 mrad < 5 mrad <.5 mrad < 2. mrad alternatively: ±4.8 V; ±9.6 V; ±4.8 ma; ±9.6 ma XY2-00 Standard, optionally optical data transfer SL status signals per axis TTL level XY2-00 Standard, optionally optical data transfer SL2-00 powerscan i Operating temperature 25 C ± 0 C Typical water requirements max. 4.5 bar 2 / 20 Information is subject to change without notice. SCANLAB AG Siemensstr. 2a 8278 Puchheim Gemany Tel. +49 (89) Fax +49 (89) info@scanlab.de SCANLAB America, Inc. 00 Illinois St St. Charles, IL 6074 USA Tel. + (630) Fax + (630) info@scanlab-america.com