BASICS OF Laser machines

–ELM& HAL
HN-UV5T2E UV Laser Marking
TOPICS AGENDA :-
1. Safety instruction about Laser Machines)
2. Interlock feed back of Machine
3. Start up and shutdown process
4. Basics function Laser machines
5. Process flow and sequences of the operations
6. Major components laser machine
7. Software interfacing
8. Basics electrical & Pneumatic systems.
Safety instruction :-
GENERAL MACHINE SAFETY :
1. Emergency stop button : If a machine behaves abnormally or shows signs of distress, it must be immediately
stopped and examined to prevent any damage to the machine. The emergency stop push button acts as a control switch
to cut off power during such situations.

2.SAFETY LIGHT CURTAINS : A safety light curtain uses an array of photoelectric sensors that when interrupted, will
send a signal to stop a machine or hazard if an area is breached.

3.Door Open sensors :

For door Open safety purpose in this machine used three no's of sensor to ensure
the door is closed condition ( front, left and right side doors its placed)
 INTERLOCK FEED BACK SIGNAL

1.Chiller control feedback to Laser

2.Chiller water temperature set point
3.Safety light curtains.
4.Machine Emergency stop
 BASICS FUNCTION OF LASER
 The Laser machine is going to make Etching marking on the particular places at mobile phones as we
required like a serial no.
 After placing the mobile on machine ,read the unit barcode and compared PDCA results with
previous station and process the etching marking.
 For etching marking we are use the UV Laser and controller ,the laser head having master and slave
unit .
 The laser machine having CCD to capture the etching process before and after ( 2D camera measure
the etching process & 3D camera is to measure the Height of the Laser point Z this offset value is
given to Z axis .
 The UV laser head is produce more heat so that reducing the laser head heat we using the cooler unit
like chiller .
 3b. SHUT DOWN PROCEDURE
step Action Schematic diagram

1. Exit the OP interface, enter the background

of the marking software, and exit the marking
1. Turn off the
software.
industrial computer
2. Exit the CCD software.
3. Turn off the industrial computer.
Marking software
CCD Software

1. Turn off the key switch of the laser control

cabinet and power off the laser control
cabinet.
2. Turn off the laser 2. Close the air conditioner of the chiller.
system 3. Press the emergency stop button and
disconnect the power supply from the circuit.
4. Turn off the equipment circuit breaker.
5. Turn off the air source.
emergency Empty
Chiller
button
3b. START UP PROCEDURE

7
 PROCESS FLOW & SEQUENCE OF OPERATION

STEP -1 :
 Place the product on the correct position of the fixer unit ,the part present sensor is sense the product it was
placed in correct location .
 Once the clamp push button pressed the unit going to clamp properly also the clamping feed back get from read
switch.
 If the Clamping its ok then scanner read the barcode of the product ,send the product's NS code to the application.
 The scanned SN data is comparing with previous station in PDCA results. The PDCA results NG its to be rework
previous stations.
STEP-2 :
 After the PDCA results ok the fixer rotate to marking position and the lock cylinder going to up and lock the fixer at
the marking position.
 The 2D CCD has capture the pre marking image to ensure if there any obstacles is on marking area.
 If 2D CCD capture any issue its shows as NG .( at the same time of camera capture OPT will ON)
 If the 2D CCD results Ok the data send to application to ready for marking.
 The 3D CCD read the Z axis value and the data has been sent to application as a Off set values.
 The Z axis Servo motor going to position to the Marking off set value from software.
 PROCESS FLOW & SEQUENCE OF OPERATION

STEP -3 :
 The laser head received the SN data form software and going to make the Etching marking
and the product as we required fonts.
 After the marking the 2D CCD is going to capture the post marking data vision with
comparing the master data ,
 If the marking data results is Ok from CCD the fixer locking cylinder went to de clamping .
 After confirming the de clamping the fixer going to rotate to loading area .
 Once the all process ok the Machine says OK and part clocking cylinder get Un lock.
 After the process complete the results is stored to PDCA.
 MAJOR COMPONENTS
1.IPC SYSTEMS
2.LASER HEAD AND CONTROLLER UNIT
3.CCD’S ( Scanner,2D&3D cameras)
4.OPT control and light source
5.Chiller unit for laser head cooling
6.Stepper motor and drive
7.Servo motor and drive
8.Pneumatics circuits
9.Electrical circuits
IPC SYSTEMS :
Introduction to Industrial PCs :
 Industrial PCs (IPCs) are specialized computers designed for industrial applications and automation process.
The IPC in Laser machine we are used Two in that one master IPC and slave IPC those the pcs going to
perform the machine function by interfacing with CCD and some other devices.
CCD CONTROLS :
The CCD is going to read the data’s from product. In laser machine the three types of CCD,s are using like Scanner,
2D camera, 3D camera.
1.SCANNER :
 Two scanner are connected along with master and slave IPC through Ethernet by data man software. This is going
to read the Product SN QR code and sharer the scanned result to IPC by using Data Man and SFC server data
base.
 Scanner specs is Cognex DM262X DC 24V is used in the laser machine.
 Scanner IP is master : Slave :
2.2D cameras :
 Two 2D cameras are connected along with master and slave IPC through Ethernet by cognex software . This is
going to capture the Product vision for recheck and recheck at the place of marking and sharer the result by IPC
and software to SFC server data base.
 If the pre check results is ok for marking then laser head going to ready for marking.
 After marking its taking the 2D camera is take a vision of marking is OK or NG by comparing the data’s with
software and its shared to SFC server.
 Scanner specs is Basler Ac 2500-14GM 24v DC is used in the laser machine.

 Scanner IP a) Master : 192.168.21.100 b) Slave : 192.168.22.100

Connection flow of 2D cameras.

Cognex
2D camera IPC SFC
software
3.3D cameras :
 Two 3D cameras are connected along with master and slave IPC through Ethernet by cognex software . This is
going to measure Z axis value of the Product marking place and sharer the result by IPC and software to SFC
server data base.
 If the pre check results is ok for marking place galvano lens is alien to the assigned the corresponding coordinates
position for marking

 Scanner specs is Cognex DS9258 24v DC is used in the laser machine.

 Scanner IP a) Master : 192.168.23.100 b) Slave : 192.168.24.100

Connection flow of 3D cameras.

Cognex
3D camera IPC SFC
software
OPT LIGHT CONTROL SYSTEM :

 OPT provides high-performance for industrial standard lenses such as scanning lens to meet the needs of
industrial vision test applications.
 To increase brightness during camera scanning, OPT lights have been included into our machine.
 The controller provides 24V as the light’s input. The light automatically turns on whenever the camera scans.
 Based on the signal received from the IPC, the OPT Light Controller is used for controlling the opt lights and
maintain light intensity up to 255 Watts Per Square Meter.
 The controller is operating with 220V input power supply . An Ethernet communications is used to interface with
the controller and IPC. It contains four ports for connecting lights.

TYPES OF OPT LIGHTS :

Bar Light Ring Light Surface light Combined bar light

CONNECTIONS AND INTERFACE OF THE OPT LIGHT :

CONNECTIONS OF OPT LIGHT OF THE OPT LIGHT : SPECIFICATION OF THE OPT LIGHT :
 NUMBER OF LIGHTS AND CONTROLLERS
OP OPT LIGHTLIGHTS OPT CONTROLLERGHTS
HAL: HAL:
12 lights used, 6 for slave and 6 It has 4 OPT Controllers
for master.
ELM: ELM:
10 lights used, 5 for slave and 5 It has 4 OPT Controllers
for master.
SSL: SSL:
16 lights used, 8 for slave and 8 It has 6 OPT Controllers
for master.
CHILLER UNSIT AND CONTROLLERS :
WHAT IS CHILLER:

A chiller is a device that removes heat from a liquid via a vapor-compression of refrigeration cycle. This cooled liquid is then circulated through a heat exchanger to cool equipment or other processes.

 UV Lasers: Require chillers due to higher heat generation, thermal sensitivity of components, precision requirements, and the need to maintain stable operating temperatures for high performance applications.

 The heat is may lead to damage the Laser head so that to reduce the heat we are using water cooling chiller and controller unit

 The chiller consist of Compressor ,Heat exchanger , radiator cooling system, Expansion valve, Filter, water tank. Extra.

 The compressor is functioning for compressing the refrigerant and enabling its continuous circulation through the system. To make the cooling process with the help of R134a Gas.

 A heat exchanger is a device used to transfer heat between two or more fluids without mixing those the liquid. Heat exchangers are commonly used in a variety of applications, from heating and cooling
systems to transfer to heat from one liquid to other liquid.
 The radiator is also as called as a "condenser." The condenser is a crucial component that plays a key role in the heat rejection process of the refrigeration cycle.it consisted of cooling fins with inside of tubes
as coil format also the cooling fins opposite .in this tube gas has circulated for reducing the heat.
 The expansion valve is controls the amount of refrigerant that flows into the evaporator The expansion valve ensures that the refrigerant enters the evaporator at the correct pressure and temperature, which is
essential for efficient heat exchange and system performance.
 The filter set up is used to remove large particles like dirt, sand, and rust from the cooling water, its made by a mesh or pleated material to trap particulates and its places at the inlet of the cooling system line.

 Water tank is used to store the cooling liquid like water .from cooling tank to laser head the water is pumping with help of the pumps .
CHILLER CIRCUITS :
LASER AND CONTOLLER:
The laser is the core component of the marking machine. If the laser marking machine model contains SHG, it means that it is equipped with a green laser with an
output wavelength of 532nm. If the model contains THG, it means that it is equipped with an ultraviolet laser with an output wavelength of 355nm. Ultraviolet light
is called a cold light source and has a minimal heat-affected zone, making it suitable for high-precision and ultra-fine marking. The laser is cooled by a chiller when
working. The laser must be used under the specified water temperature to achieve the best effect.

The system composed of X, Y scanning galvanometer and driver is used for high-precision scanning and precision
positioning of laser. This system adopts high-stability galvanometer system, which has strong anti-interference and no zero
drift. The galvanometer adopts high-stability precision position detection sensor technology and moving magnetic and moving
coil deflection working mode design. The driver adopts a new topology circuit design, and outputs a servo signal to control
the galvanometer deflection under computer control, so as to accurately print the graphics.
b) Scanning mirror and driver

The system composed of X, Y scanning galvanometer and driver is used for high-precision scanning and precision positioning of laser. This system
adopts high-stability galvanometer system, which has strong anti-interference and no zero drift. The galvanometer adopts high-stability precision
position detection sensor technology and moving magnetic and moving coil deflection working mode design. The driver adopts a new topology circuit
design, and outputs a servo signal to control the galvanometer deflection under computer control, so as to accurately print the graphics.

c)Lens :

The F-ÿ lens can focus the laser beam into a small spot. The characteristic of the F-ÿ flat field lens is that no matter how the beam moves, the focus
point position always remains on a plane, ensuring that the spot size and energy density are consistent in the marking area, improving the quality of the
mark. The double-station laser marking machine adopts the rear focusing method. The F-ÿ lens is installed behind the galvanometer scanner, and a
good focusing effect can be obtained in the two-dimensional working area perpendicular to the optical axis.
PNEUMATIC CIRCUIT :
4 to 5 bar 1bar=100000pa An FRL (Filter, Regulator, Lubricator) unit is an essential component in
many pneumatic systems. Here’s a breakdown of each component:
 SOFTWARE INTERFACING

1 . OPT CONTROL:
 The OPT control software is going to interfacing with flash light operation of camera to clear vision
capturing of the product .
 The OPT having six no’s of light source and controller unit
 The OPT controller is connecting through Ethernet IP via TP link set up.

 2.DATA MAN :
 The data man software is interfacing with the part scanner to read the barcode of the product SN.
 This going to communicating the two scanner master and slave
 Both scanner having individual IP address for software interface.

3. COGNEX :
 The cognex software is interfacing the vision cameras.
 The cameras communicating with Ethernet IP
 All cameras have individual IP address for software interface.