500WLaser mold welding

machine manual

Laser working Nd3+:YAG

substance
Laser wavelength 1.064m
Output average power 500W
Laser pulse width 0.2~20ms Continuously adjustable
Pulse repetition 1~150Hz Continuously adjustable
frequency
Maximum single pulse ≥150J
energy
 200W 激光模具焊接机说明书

Maximum input power 16KW

Product Summarize

The surface of the metal will be changed by the laser, it has been heated and
conducted to the deepper of metal rapidlys, and the surface will be melted when
the consistency of laser power is enough, some parts is momentary vapored for
the high consistency ,and it is come into being the weld crater.

The laser welding compares with other welding craft can realize the very many
material welding, compares has the superiority, welds the component thermal
deformation to be small, the attachment quality is high. The laser welding
superiority in with can realize partially the very small scope heating characteristic,
widely uses with the precision component like jewelry, the battery, the
automobile industry, aviation industry some other applications and so on.

The LS-TW200 laser welding apparatus are the pulse welding way, in the
welding the pulse energy and the pulse width can adjust, pulse energy influence
melting quantity, width influence melting depth. Meanwhile adjusts the weld
point through the outside path of rays adjustable expender to adjust the focusing
faculae the size.

ls-TW200 laser welding system is a new improved product. It can be used to

process the spot welding and seam welding for many small scale metal
components, such as Titanium, Nickel, Aluminum, Stainless steel, Gold,
Argentine, Copper, Platinum and so on. It can process the spot welding on the
contactor of the relay, the steel strip of the computer floppy disk driver, the pins
of the printer, and also process the seam welding of the metal tube and belt, the
core of the servo motor, process the sealing welding of the cover of the relay, the
IC package, the pressure device, the cover of the heart pacemaker, the cover of
the Tantalum capacitance and Lithium battery, etc.. It also can be used to cut and
drill the small scale metal components.

2
 200W 激光模具焊接机说明书

This system is especially suitable in the jewelry industry. There is no special

block needed during the processing. The pieces to be processed can be hold by
hand, and to be welded under the microscope conveniently.

1. Device Configuration

The main components A brief description

Φ7 excellent grade YAG crystal, ceramic

Laser
concentrating cavity.

Laser power supply LWY200 pulse power supply

Dedicated cooling Integrated dedicated chiller, over temperature alarm,

system flow protection.

Control System Single chip microcomputer

Observation system 10x microscopic observation system

2. Main technical indicators

2.1. Laser
Working substance: Nd3:YAG
Wavelength: 1.06m
Pulse xenon lamp: repetition rate pulse xenon lamp
Pulse frequency: 120Hz continuously adjustable

3
 200W 激光模具焊接机说明书

Pulse width: 0.2~20ms graded adjustable

Single pulse energy: 050 joules
Power: 200W

2.2. Solder joint size

The diameter is 0.21.5mm, which can be adjusted as required.

2.3. Optical system

(1) Laser beam expansion and focusing
Beam expansion ratio: 3 times
Focusing objective lens focal length: 100mm

2.4 cooling system

The dual-cycle water cooling system is used to cool the laser and the pump lamp,
driven by a magnetic pump, and protected by an over-temperature controller. The
inner circulating water is made of deionized water having a resistivity greater
than 0.5 M-cm. The heat of the inner circulation is taken away by the refrigerator,
and finally the heat is discharged into the atmosphere by the fan.

2.5. Power Requirements

Single phase, AC 220V10, 6KW

2.6. Working environment

The surrounding environment is clean, away from strong vibration sources,
temperature 10 ° C 32 ° C, humidity below 85%.

2.7. Continuous working hours

he continuous working time of the whole machine is more than 8 hours.

2. Structure Introduction and Maintenance Guide

The whole machine consists of five parts: laser, power box, optical processing system,
control box and cooling system. According to the function can be divided into:
(1) Laser (2) Laser power supply (3) Optical system (4) Control system (5) Cooling system

4
 200W 激光模具焊接机说明书

3.1 laser
3.1.1. Introduction to laser structure

The laser is a device that converts electrical energy into laser energy. This
machine uses a Nd3:YAG laser. It mainly consists of the following parts: (1)
pump lamp (2) laser rod (3) concentrating cavity (4) optical cavity (5) other
auxiliary parts
The pump lamp converts electrical energy into light energy and "excites" the
laser working substance. This machine adopts the repetition rate pulse xenon
lamp. The surface of the electrode and the quartz glass tube of the lamp need to
be cooled during operation. The laser bar converts the light energy into laser
energy. The machine uses Nd3:YAG rod as the working substance.
The concentrating cavity focuses the lamp pump light onto the working substance,
and the machine adopts a tightly packed ceramic cavity.
The optical cavity provides optical feedback that amplifies the laser to form a
high intensity laser output. This machine adopts a parallel plane cavity and is
composed of a plane mirror coated with a high damage threshold dielectric film.
When the laser is working, only about 3 of the energy supplied by the power
source is converted into laser energy, and most of it is converted into heat energy,
which is distributed on the pump lamp, the laser rod and the concentrating cavity.
In order to protect the normal operation of each part, it is necessary to take away
the heat. This machine uses circulating deionized water to cool the lamp, rod and
cavity.
In addition to the above main components, the following accessories are
available:
(1) high voltage trigger pole, (2) insulating bottom plate, (3) positioning bracket,
(4) two-dimensional adjustable diaphragm frame, (5) laser frame.

3.1.2. Precautions and maintenance

The laser machine is a high-tech device integrating light, machine and electric technology. Its
equipment is relatively precise, and the operation and maintenance personnel must have the
expertise and technology to work.

5
 200W 激光模具焊接机说明书

A. Optical cavity
The two dielectric diaphragms constituting the optical cavity are strictly parallel with the end
face of the laser rod during operation, so that the optical resonator is not allowed to be
touched and arbitrarily adjusted after being adjusted. In addition, each optical surface must be
kept highly clean, otherwise the high-energy laser beam will damage the film, so do not open
the laser cover at will. When the laser output energy drops, first check whether the media
diaphragm is clean. If there is dirt, use lens paper or absorbent cotton dampening solution (50
mixture of absolute ethanol and ether, the same below) to gently wipe, and then Check if the
cavity is out of regulation.
B. Cooling system
The laser has an inlet pipe and an outlet pipe, which are respectively connected to the lamp
and the rod cooling channel. When the water flow is not smooth anywhere, it may cause
irreparable damage. Every time you reassemble, you should check the flow of each channel
to ensure that the laser can be turned on without any errors.
C. Changing lights
The pulsed xenon lamp is a consumable part, and the average service life at rated power is
106 flashes. In order to ensure the normal operation of the machine, after the lamp has been
working for the rated number of times (about 106 times), it must be replaced when the energy
drops. The empirical formula for determining the number of rated flashes is as follows:
8.58
 Explosive energy 
Rated flash count   
 Actual injection energy 

The xenon lamp should also be replaced if the xenon lamp is damaged by other factors or the
actual life is shortened (in the case of a failure to predict or the voltage is raised to 500V,
there is still no energy output).
Due to the low strength of the transition glass sealing section at both ends of the xenon lamp
used, special care must be taken when replacing it. The steps are as follows:
(1) Shut down, stop water, and release the remaining charge on the storage capacitor.
(2) Remove the lamp electrode.
(3) Remove the lamp cover and carefully pull out the xenon lamp from the side of the full
mirror.
(4) Clean the casing with a cotton dampening solution.
(5) Check if the appearance and size of the new xenon lamp meet the requirements.
(6) Insert the lamp into the cavity, press the gland, and install the electrode.

6
 200W 激光模具焊接机说明书

(8) Check the sealing of each part by water.

(9) Turn on the main power check light to discharge normally.
(10) Check whether the laser output energy meets the requirements with a single point
condition. If the output is not ideal, the cavity should be adjusted repeatedly.
(11) Cover the laser cover.
D. Nd3+: operation of the YAG rod
Nd3+: YAG rod is the core of the laser, so be careful when installing it. Nd3+: The end faces
of the YAG rod are strictly parallel and the finish is very high. If the end face is found to be
contaminated, the room must be cleaned first, and then trained by professionally trained
personnel. Remove the Nd3+: YAG rod and use a lens paper or absorbent cotton dampening
solution (50 mixes of absolute ethanol and ether) to gently wipe the stain. The causes of
damage to the rod are:
a. The cooling water flow is too small or interrupted, and the energy injected in the lamp
causes the lamp and the rod to overheat and cause the lamp and the rod to burst.
b. Touch and scratch with a hard object to damage the end face.
c. End face contamination, the film is burned out when the high intensity laser passes.
d. If the pressure is too tight or the pressure is uneven, the rod will burst due to excessive
internal stress. For this reason, equipment operators generally do not open the laser cover, nor
do they operate the YAG rod. If the end surface is found to be contaminated, it should be
handled by professionally trained personnel.
E. Maintenance of the concentrating cavity
The concentrating cavity uses a ceramic concentrating cavity, which has high reflectivity and
does not require maintenance. Generally, the concentrating cavity is not allowed to be
disassembled.
F. High voltage protection
In order to make the laser work, three kinds of voltages are added to the pulse xenon lamp,
namely the trigger voltage, about 1.52 volts, the open circuit voltage is 1700 2000 volts, and
the arc discharge voltage is about 5001900 volts. In addition, the lamp electrode and other
metal parts should not be too close, at least 15mm or more. In use, care should be taken to
keep the surface of the insulating base plate dry and clean, so as to avoid a high voltage short
circuit caused by a decrease in insulation performance after contamination.

3.2 laser power supply

This unit is equipped with an operation panel and a joystick. The operation of the laser can be
controlled by operating the panel buttons or the joystick.

7
 200W 激光模具焊接机说明书

3.2.1. Main technical performance and indicators

The power supply of the machine is a repetition rate pulsed laser power supply system. The
charging circuit adopts LC resonant charging. The energy storage uses a capacitor-inductive
energy storage network to control the power supply through the IGBT switch tube. The
control circuit is based on two single-chip microprocessors. It can easily adjust the output
energy and repetition rate of the power supply, which can adjust and operate the power
system independently, and can operate online with the control system. Multiple linkage
protection is provided in the system to ensure that the main power can be cut off immediately
under abnormal conditions.

3.2.2. Circuit description

The circuit is mainly composed of the following parts:
Main circuit: including charging circuit, energy storage network, discharge circuit and
pre-ignition and trigger circuit.
Control circuit: including electrical control circuit, microcomputer control circuit and various
protection circuits.
A. Boost/rectifier circuit
The boost/rectifier circuit converts 220V AC to 620V DC through single-phase boosting to
provide power to the charging loop.
B. Charging circuit
The charging circuit is composed of a voltage doubler circuit, and this charging method can
increase the repetition rate of the circuit.
C. Discharge circuit
The discharge loop is controlled by a thyristor and the discharge IGBT must remain off.
After the energy storage network is charged, the charging IGBT is turned off, and after a
delay, the discharging IGBT is turned on and discharged, the storage capacitor is discharged,
and the IGBT is turned off by itself.
D. Pre-ignition and trigger circuit
It includes a step-up transformer, a high voltage rectifier bridge, a filter, a current limiting
resistor, a current relay, a high voltage pulse transformer and a high voltage trigger circuit.
Since the pulsed xenon lamp enters the normal glow discharge state during pre-ignition, it
has a negative resistance characteristic. In order to make the xenon lamp discharge in the arc

3.3 optical system

8
 200W 激光模具焊接机说明书

3.3.1. Binocular stereo microscope

For clear observation and stereo vision, this machine uses a binocular stereo microscope. In
order to prevent contamination of the objective lens by metal vapor splash during laser
processing, a coated protective glass is added in front of the objective lens, and a
large-caliber long focal length microscope objective lens is shared by the binocular path.
Loosen the fixing screws to easily remove the eyepiece section for easy transportation and
maintenance.

3.3.2. Laser beam expanding and focusing system

In order to ensure that the laser welding spot is always in the center of the field of view
during the focusing of the workpieces at different heights, the laser beam needs to be coaxial
with the microscope optical path. This machine adopts laser and microscopic optical path
common objective lens design. The size of the defocus amount is adjusted by the button. The
amount of defocus is determined by the welding process and determined by experiment.

3.3.3. Solder joint indication

Since the YAG laser is 1.06m invisible infrared light, in order to indicate the
laser position, there is a crosshair in the eyepiece, and the intersection of the
crosshairs coincides with the laser spot, so that the laser beam can be easily
aligned with the portion to be welded of the workpiece to be welded. .。

3.3.4.Optical system use precautions

(1) It is strictly forbidden to touch the surface of each optical component by hand,
cotton yarn or hard object. It is also forbidden to blow the air to the optical component
with the mouth. Only use a blown balloon to blow off the dust. In case of pollution,
use long-fiber cotton or lens paper. Wipe gently with the cleaning solution.
(2) Do not disassemble parts to avoid damaging the parts and dust from entering the
optical system.
(3) When adjusting the focus of the push-pull lens cylinder, be careful not to touch the
protective mirror. To replace the protective glass, remove the lens barrel of the
objective lens and unscrew the pressure ring. Be careful when replacing it.

9
 200W 激光模具焊接机说明书

3.4 cooling system

3.4.1. structure
The cooling system is an integral part of the laser equipment. It consists of a heat
exchanger, a magnetic pump, a filter, a water storage tank, a flow switch and a
temperature contact, an ABS engineering plastic pipe, and a valve to form a
closed water circulation system.

3.4.2.Principle of action
The inner circulating deionized water in the water tank is pumped by a magnetic pump, and
the working substance (YAG rod), the pulse lamp and the two lamp electrodes of the laser
are water-cooled, and the desorbed water after the heat absorption flows back to the water
tank through the heat exchanger. Deionized water generally requires a resistivity of 0.5M-cm.
If the resistivity of deionized water is reduced after a period of use or impurities, dirt, and
water become turbid in the water, the Xe lamp will not burn or pollute the laser cavity. Glass
tubes reduce efficiency. Deionized water should be replaced immediately (replace the
deionized water in the system once a week for continuous use).

10
 200W 激光模具焊接机说明书

4. Installation

4.1 Installation conditions

Due to the precision optics used in laser welding equipment, the machine should
be installed in a position that meets the following requirements for proper
operation.
project Installation conditions Remarks
Ambient Condensation
15-35 degrees
temperature is not allowed
environment
30-80%
humidity

dust Less than 0.20mg/m3

Oil mist Not allowed

Distribution
1 single phase AC cabinet
power supply
50Hz/60HZ ≥25A provides main
power

Cooling water 2 voltage within ±10% All-in-one 10L

5. Operating instructions

11
 200W 激光模具焊接机说明书

5.1. Panel operation instructions

Note: Please read this operation carefully before starting to operate the
LWY200 laser welding machine.
Panel description to avoid malfunction or damage to the laser caused by
incorrect operation!
5.1.1 Power On
When the power is transported over long distances, check it before starting it:
1. Whether the printed board is loose;
2. Whether the device has signs of falling off;
3. Whether there is any sign of looseness at the contact of the line nose;
4. All external wiring (power cable, wiring between power boxes) is correct;
When you are sure that all the connections are correct, first close the air switch, turn on
the power, and then turn on the control circuit. The touch screen of the power is lit as shown
in Figure 5-1. The power supply starts self-test. Check the power supply water protection,
whether the charge and discharge part is normal. If the detection is not normal, the system
detection abnormality will be displayed.。

图 5-1
After the power-on self-test is successful, press the “Start” button to start the power supply.
After about 40 seconds, the power contactor is pulled up. After 10 seconds, the
pre-combustion circuit works. The high-voltage lamp of the Xenon lamp is pre-ignited. After
2 seconds, the power touch screen whistle. The power is turned on successfully.
Note: It takes about 1 minute for the system to start normally. During the startup
process, it is forbidden to perform any operation on the touch screen!

12
 200W 激光模具焊接机说明书

图 5-2
3.2 Welding waveform
a) The right menus “Start” and “Stop” are the power switch button, “Enable Light”
is the enable light button that is added when the machine is out of light. “Other” is mainly
used to set the import interface of other functions.

图 5-3
a) Main status display of power supply: Figure 5-1 shows the status of the current power
supply box "Discharge: Normal", showing the current pre-ignition status "Pre-ignition:
Normal", showing the current temperature status of the IGBT module "Temperature: Normal
", the current water tank status "waterway: normal" is displayed. The light exit point of each
pedal is "single: 388", and the total number of light exit points is "total: 888888".
b) Waveform storage number selection: Touch “Program” with your finger or touch pen to
enter the dialog box. In this dialog box, you can enter the number and change the value of the
program number. Starting from waveform 0, you can select 33 groups of waveforms. .
Different pulse width, frequency and current setting waveforms can be set for each set of
waveforms.

13
 200W 激光模具焊接机说明书

c) Current setting input: Touch “Current” with your finger or stylus to input the dialog box,
and input the current to be input in the pop-up digital input window.
d) Pulse width setting input: Touch “Pulse width” with your finger or stylus to enter the
dialog box. Enter the size of the pulse width to be input in the pop-up digital input window.
e) Light output frequency setting input: Touch “Frequency” with your finger or touch pen
to input the dialog box. Enter the frequency to be input in the pop-up digital input window.
The frequency input range is 0HZ—150HZ. At 0HZ, the machine works in jog mode. In this
way, stepping on the pedal will only output a laser pulse. If you need to output another laser
pulse, you must first release the pedal and step on the pedal again. When 1HZ---150HZ, the
machine works in continuous light-emitting mode. When the pedal is depressed in this mode,
the machine continuously outputs laser pulses at the set frequency. After releasing the pedal,
the light stops.
Note: The parameter setting interface needs to adjust the parameters with the joystick.
Move the joystick up and down and left and right to see the flashing cursor on the
screen move on the “waveform”, “current”, “pulse width” and “frequency” to
change the parameters.

3.3 Single point compensation

Touching “Single Point Compensation” with your finger or stylus will bring up the
dialog box shown in Figure 5-4. This function is to provide customers with a single
point repair function. Now the power supply is generally stronger than the previous
points. In the low case, it can be improved. For example, if the previous points are
strong, the percentage of the previous points can be adjusted appropriately. If there is a
point in the middle that needs to be stronger, the percentage of this point can be
increased a little. The dot percentage is adjustable from 40% to 150%.

14
 200W 激光模具焊接机说明书

图 5-4
"Total points" is the number of points that need to be played when playing a
product. The total point set cannot be greater than 32 points. How many points
are set has compensation function, and there is no compensation function after
the total number of points. The percentage is 100%. "Interval time" is the interval
between the time when the first product is hit and the time when the second
product is hit, that is, the interval between two pedals. For example, when the
"interval time" is set to 1S, the pedal is stepped on. The interval between the two
times is 0.5S. At this time, the power supply considers that the pedal signal is not
disconnected and the signal is always given.
Note: The single point compensation function can only be used when displaying this
interface!
3.3 Band
In addition to the basic parameter configuration, the system also provides the function of
segment programming. The definition of segmentation is to divide a group of programs into
multiple segments. The system supports 15 segments of programming. The default segment
number is 1 for non-segment programming. That is, only one segment is configured.

15
 200W 激光模具焊接机说明书

图 5-5
Taking the 5-segment programming as an example, the requirements are as follows:
Frequency 10Hz
The first paragraph: 100A 1ms
Second paragraph: 200A 1.5ms
Third paragraph: 150A 1.5ms
Fourth paragraph: 120A 0.8ms
Fifth paragraph: 220A 2ms
The operation process is as follows:
1. Set the frequency 10Hz in Figure 5-1. Click the “Band” button on the right to enter
Figure 5-5.
2. Click on “Add Band” to add 5 bands.
3. Enter the parameters of the first segment - the fifth segment current and pulse width
respectively.
4. Click “Band Display” to display the waveform of the current parameter in real time
in the left waveform display. If the pulse width of segment 1-5 is assumed to be t1 - t5, the
waveform is shown in Figure 5-6.

图 5-6
It should be noted that the pulse width value after segment programming is the sum of the
pulse width values of each segment. Therefore, it is necessary to ensure that the total power
after programming is within the allowable range of the device, otherwise a new segment will
not be allowed to be added. To delete a segment, simply set the pulse width value of the

16
 200W 激光模具焊接机说明书

segment to Note: The band function can only be used when displaying this interface!
3.4 Other settings
Touching “Settings” with your finger or touch pen will bring up the dialog box shown in
Figure 5-6. This interface can set the screen time, the total number of light output is cleared,
the Chinese and English are switched, and the power usage period is set. The valve switch
delay can set the delay time before and after the switching light of the valve. It can be
switched between mold welding and galvanometer welding. When the galvanometer welding,
the liquid crystal light valve is not enabled. When the pedal is stepped on, the light is
immediately emitted without delay.

图 5-6
Password permission setting
Amortization can be implemented using a password. If the password program has not been
unlocked by the time, it will automatically stop working. Just enter the password for this
period and it will be used normally. Click Figure 5-6 “Unlock” to enter the administrator
password “554018”, and Figure 5-7 appears to set the password. "Password 1-3 Expiration
Time" can be set to three groups, three times to limit the password protection time, can
achieve three times to lock the power on. "Password 1-3 Protection Password" is the unlock
password for the three sets of password protection respectively set. "Password 1-3 Save" is
activated by clicking this button after setting the time and password. When the setting is
completed, click “Back”, as shown in Figure 5-10, the “Password Permissions” button
disappears and you cannot enter the set password again. When the administrator password
"551840" is entered, the previous setting password is cleared to display the "Password
Permissions" button to modify the password again.

17
 200W 激光模具焊接机说明书

图 5-7
3.5 No light
When the power is not in use, the laser output is not allowed for safety. Click the right button
"No light out" will appear "Enable light", switch between the two.
When stepping on the pedal screen when “ Forbidden Light Exit ” is displayed, it will
display as shown in Figure 5-8, and no light will be emitted. Only when the point “Enable
Light Exit” can the laser be emitted.

图 5-8

5.2.Boot sequence:
1. Close the power knife
2. Open the key switch
3. Start the laser by selecting the boot option as √
4. After the startup status is displayed as “Startup Completed”, press the foot switch and the
laser light is emitted.

18
 200W 激光模具焊接机说明书

5.3.Shutdown sequence:
1. Select the startup option to ×, turn off the laser
2. Close the key switch
3. Disconnect the power knife

Note:
There are red emergency stop buttons on the right side of the machine surface
and inside the operation room for emergency use. Press to cut off the power
of the equipment immediately.

Water tank operation

After the device key switch is turned on, the water tank power supply is
automatically powered on. Please do not operate any power on/off directly on the
water tank after turning on the power.
5.4.Welding position adjustment:
When the laser is in operation after startup, the workpiece to be welded can be laser welded.
First, select the appropriate welding parameters according to the characteristics of the
workpiece to be welded, such as pulse width, frequency, working voltage and defocusing.
After the parameters are set, the workpiece to be welded is observed through the eyepiece of
the stereo microscope, and the workpiece to be welded is moved up and down to make the
workpiece image clearest in the field of view, and the intersection of the crosshairs in the
eyepiece coincides with the workpiece to be welded. When the foot switch is pressed, the
laser light is used to weld the workpiece to be welded. If the weld point is not in the same
position as the intersection center, the position of the center point of the cross needs to be
adjusted.
In the output section of the external light path of the operating room, there are two screws for
fine-tuning the laser relative to the center of the cross. Turn on the red light indicator,
observe the surface of the workpiece to be welded through the eyepiece of the microscope,
check if the red light is at the center of the cross, and if it is off, adjust the position
adjustment screw in the operation room;

19