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Laser Mech FiberMINI 2.0 Operation Manual

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Operation Manual

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SURAJ KUMAR SAHU
March 5, 2025

QBH60/125 NO HSU document

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Summary of Contents for Laser Mech FiberMINI 2.0

  • Page 1 FiberMINI ® Operation Manual...
  • Page 2 Mechanisms, or use of this product. Inc. authorized personnel. ® Laser Mech is a registered trademark of Laser For complete warranty information visit our web site Mechanisms, Inc. at www.lasermech.com.
  • Page 3 INITIAL INSPECTION TERMS USED IN THIS MANUAL Inspect all shipping containers for damage as soon WARNING: The user could be injured as the device arrives. It is your responsibility, the if the warning is not followed. recipient, to notify the freight company of any damage.

  • Page 4: Table Of Contents

    Table of Contents Introduction ................................1 Mechanical Installation ............................2 Mounting ............................. 2 Plumbing ............................. 2 Cable Bundling ............................ 3 Fiber Adapter ............................3 2.4.1 Fiber Insertion ........................5 2.4.2 Fiber Orientation Adjustment ...................6 Electrical Installation ............................7 Electrical Connections ........................7 Electrical Grounding and Noise ......................8 Control Box Mounting .........................
  • Page 5 Service................................22 Servicing Gas Jet Tip ........................22 5.1.1 Heads with Height Sensing ................... 22 5.1.2 Heads without Height Sensing ..................22 Cleaning Optics ..........................23 Servicing the Cover Glass ........................ 25 Servicing the Tip Retainer Assembly ....................26 5.4.1 Heads with Height Sensing ...................
  • Page 6 Appendix A – Interface Specifications ......................50 10 Appendix B – Example of Integrating the HSU to a PLC/CNC ..............53 11 Appendix C – Changing the Focal Length ....................55 12 Appendix D – Configurations......................... 56 13 Appendix E – Service Dimensions ........................ 60 14 Appendix F –...

  • Page 7: Introduction

    FiberMINI 2.0 is available in Appendix D – many diverse configurations. See Configurations and the supplied assembly drawing to identify the components in your ® custom FiberMINI 2.0 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...

  • Page 8: Mechanical Installation

    2.2 Plumbing 2 Mechanical Installation  Water Cooling Appendix E – Service Dimensions FiberMINI™ 2.0 processing heads are helpful assembly dimensions and notes. equipped with a water-cooling circuit. 2.1 Mounting  It is recommended that power levels greater than 1kW use water cooling. ®...

  • Page 9: Cable Bundling

     Assist Gas  Purge Gas and Air Cooling See Figure 5 for location and hose size. See Figure 5 for location and hose size.  Maximum pressure is 20 BAR.  Purge gas pressure is 0.2 – 0.3 Bar (3.0 –...
  • Page 10  The head arrives with the adapter for the requested fiber end style. Part Number Fiber End Style PLFIA0001 PLFIA0003 QD/LLK-D PLFIA0006 Q5/LLK-B Appendix F – Fiber End Styles samples of each.  The fiber can be supplied with a collimator, but can also accommodate a third party collimator.

  • Page 11: Fiber Insertion

    2.4.1 Fiber Insertion It is the responsibility of the end user to verify that the correct fiber type is installed according to manufacturer specifications. Appendix F – Fiber End Styles more information. To access the fiber installation location (see Figure 7): 1.

  • Page 12: Fiber Orientation Adjustment

    2.4.2 Fiber Orientation Adjustment Many fiber optic cables are keyed and will only fit into the fiber interface adaptor (FIA) in one orientation. The FIA can be rotated to match the orientation of the fiber coupler and reduce twisting of the fiber optic cable. To reorient the connector on the FiberMINI™...

  • Page 13: Electrical Installation

    3 Electrical Installation 3. Insert the right angle end of the tip wire into the tip retainer assembly. 3.1 Electrical Connections There are (4) connection locations for the There are two connections to the height control box. sensing unit (PLHSU0073) and one to the For steps 4 to 6, see Figure 10.

  • Page 14: Electrical Grounding And Noise

    3.2 Electrical Grounding and Noise The capacitive sensing circuitry contained in the FiberMINI™ 2.0 cutting head measures minute changes in electrical capacitance between the tip and earth- ground to determine tip-to-part standoff distance. In order for this circuit to function properly the part and the cutting head need to be connected to a good earth ground.

  • Page 15: Control Box Mounting

    3.4 Interface Signals 3.3 Control Box Mounting 3.4.1 V Standoff (Analog Out) The control box mounting pattern is illustrated in Figure 12. Important things to The V analog output is consider when mounting the control box proportional to the distance between (PLEBX0063): the sensor and the target material.

  • Page 16: Vref (Analog Input)

    Most digital servo amplifiers with a software interface can be 3.4.4 Ready (Digital Output) considered Intelligent. They will use When active, this output indicates a variety of methods for generating that the system is operating the Error Detection stage of the normally.

  • Page 17: Status (Digital Output)

    The height sense electronics are designed to operate with dynamic 3.4.6 Status (Digital Output) stability control of the nozzle The Status output is a handshake standoff. for the calibration input (CAL). When  the sensor is requested to calibrate, Nozzle standoff control is this signal will become active.

  • Page 18: Internal Illumination

    3.5 Internal Illumination Internal illumination is an option on all vision systems. Plug it in according to Figure 15.  A 5VDC 300mA power supply is included with each vision system. Figure 15 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...

  • Page 19: Operation

    4 Operation 5. Open the Digital Microscope Suite It is essential to any laser process that the software. beam be centered in the gas jet tip. It is the customer’s responsibility to center the laser 6. Install the beam centering camera beam in the tip orifice.
  • Page 20 7. Adjust the camera focus knob (see 11. Use a 1/8 inch hex wrench to loosen Figure 16) until the end of the gas jet or tighten the (2) adjuster screws so tip nozzle becomes in focus with a the beam is centered in the nozzle clear image.

  • Page 21: Centering The Beam In The Tip Orifice Manually

     For a third party collimator: 4.2 Centering the Beam in the Tip Orifice Manually 4. See Figure 21 and center the beam inside the tip orifice using the If desired, this procedure can also be following: performed using the centering tool (PLFXT0236).

  • Page 22: Setting The Focus Position

     For a Laser Mechanisms’  The position of the focal point will be collimator: approximately at the end of the tip when the Focus Dial Knob is set at 4. 7. See Figure 22 and center the beam inside the tip orifice using the following: For example, when the Focus Dial Knob is at 5, the...

  • Page 23: Using The Basic+ Control Box

    4.4 Using the Basic+ Control Box 4.4.2 Connecting 4.4.1 Introduction Connect the USB cable to your PC. If this is your first time connecting Basic+ HSU Utility is PC software the cable, you will need to wait for that provides a user interface for the the drivers to be installed.

  • Page 24: Hsu Panel

    4.4.3 HSU Panel 4.4.4 Settings The HSU Panel provides an See Figure 26. Selecting Show interface to functions performed by HSU Settings in the Settings menu the unit located on the laser head. or clicking the small arrow in the See Figure 25.

  • Page 25: Basic+ Panel

     Active Curve  Averaging Sample See Figure 27. Clicking on the Active Curve number will open the When the HSU measures the Curve Selection Window. This capacitance between the tip and the window displays graphical work-piece, it will average this representations of the curves number of sampled readings.
  • Page 26 On the left side is the Ground Navigate through the tabs to locate Voltage check. This meter is used to the picture and part number that verify that the voltage reading at matches your TRA. If you are ground is close to zero. The upper unable to find your exact model, limit can also be specified by please contact Laser Mechanisms...

  • Page 27: Load Curve

    4.4.6 Load Curve The Load Curve selection in the When the curve data is transferred a Settings menu allows you to upload pop-up screen will appear that says “Curve Successfully Loaded.” Click new curve data to your HSU. Choose the appropriate height sense curve file (.hsc extension) in After the curve data is transferred to the pop up screen that appears.

  • Page 28: Service

    5 Service Appendix E – Service Dimensions helpful assembly dimensions and notes. 5.1 Servicing Gas Jet Tip 5.1.1 Heads with Height Sensing 5.1.2 Heads without Height Sensing See Figure 31. See Figure 32. To remove the gas jet tip: To remove the gas jet tip: 1.

  • Page 29: Cleaning Optics

    5.2 Cleaning Optics Optics are very sensitive to dust and DO NOT USE AN AIR COMPRESSOR. debris. It is extremely important to take every possible precaution to ensure the optics remain pristine. 5. Secure the optic by its edge with the curved ...
  • Page 30 13. With the soaked lens tissue gently scrub the 18. Reassemble the optic according to the optic with a circular motion, then slowly wipe appropriate section of this document. in one direction.  Recommended best practices include: 14. Turn the optic over (flat side facing up). Blow any dust, lint, debris, etc.

  • Page 31: Servicing The Cover Glass

    5.3 Servicing the Cover Glass The cover glass can be changed while the head is mounted to the robot by using the procedure that ® The cover glass for the FiberMINI 2.0 is follows: located between the focus adjustment controls and the tip retainer assembly. See Figure 33.

  • Page 32: Servicing The Tip Retainer Assembly

    5. Take the cover glass holder to a clean 5.4 Servicing the Tip Retainer area. Assembly 6. Remove the cover glass from the holder by applying pressure with your Before opening any part of the fingers to the surface of the cover head, clean off the dust and/or glass, opposite the seal.
  • Page 33 For steps 2 to 7, see Figure 37. To remove the tip retainer assembly: 2. Note the orientation of the tip wire connector for reinstallation of the tip retainer assembly. 3. Using the retainer nut, unthread the tip retainer assembly from the lens manifold block spacer.

  • Page 34: Heads Without Height Sensing

    5.4.2 Heads without Height Sensing See Figure 38: To remove the tip retainer assembly: 1. Using the retainer nut, unthread the tip retainer assembly (PLTRE0331) from the lens manifold block spacer. To replace the tip retainer assembly: 2. Verify that the engagement boss o-ring (PLORG0040) is in place in the top of the tip retainer assembly.

  • Page 35: Servicing The Focus Lens

    5.5 Servicing the Focus Lens The focus lens can be changed while the head is mounted to the machine by using the procedure that follows: Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.

  • Page 36: Removing And Replacing The Collimator

    6. Take the lens holder retainer nut to a 12. Align the adjustable lens holder clean area and invert it to remove the spacer and tighten the (4) captive M4 lens. SHCS, if necessary.  Note the location of the seal ring. 13.
  • Page 37 To remove the collimator assembly: See Figure 41. 1. Remove the fiber from the collimating assembly. Each fiber style has a unique method of securing it to the fiber input adapter. Refer to the fiber manufacturer’s information for specific instructions. Remove the fiber with great care.

  • Page 38: Servicing The Head Electronics

    5.7 Servicing the Head Electronics See Figure 42. 1. Turn off power to the head. 6. Align the new height sensing unit and flat gasket (PLGSK0002). 2. Unthread the 14-pin connector for the communication cable (PLCAB0489) 7. Tighten the (4) M3 SHCS that secure on the top of the height sensing unit the height sensing unit to the head.

  • Page 39: Optional Vision Systems

    5.8 Optional Vision Systems  The right angle vision option The purpose of the camera mount is to mounts horizontally above the fiber provide visual observation of the operation input. See Figure 45. as it is performed. One camera mount assembly (PLCMA0009) is available.

  • Page 40: Servicing The Camera Mount

    5.8.1 Servicing the Camera Mount The M4 SHCS and the 4 mm dowel Before opening any part of the head, pins are located in the camera mount clean off the dust and/or process assembly. debris using an exterior cleaning  towel (PLTLS0023) or equivalent.

  • Page 41: Camera Specifications

    See Figure 49 for the offset style camera mount. 5.8.2 Camera Specifications Laser Mechanisms camera PLCAM0002 (see Figure 50) is available as an option. It meets the specifications in the table below. If you supply a camera, it must also meet these specifications.

  • Page 42: Adjusting The Optional Camera Mount

    5.9 Adjusting the Optional Camera 5.10 Servicing Vision Components Mount 5.10.1 Fixed Mirror Holder The vision system is usually adjusted after Before opening any part of the laser focus position is found and the head head, clean off the dust and/or is located in the proper laser focus process debris using an exterior position above the work piece.

  • Page 43: Mirror Retainer

    5.10.2 Mirror Retainer To replace the mirror retainer: Before opening any part of the head, 3. Place the optic (new or cleaned clean off the dust and/or process according to Section 5.2) into debris using an exterior cleaning the fixed mirror holder with the towel (PLTLS0023) or equivalent.

  • Page 44: Beam Bender

    5.10.3 Beam Bender 5.10.4 Splitter Cap Before opening any part of the head, Before opening any part of the head, clean off the dust and/or process clean off the dust and/or process debris using an exterior cleaning debris using an exterior cleaning towel (PLTLS0023) or equivalent.

  • Page 45: Accessing Fibermini Mirrors

    ® 5.11.2 Straight Vision 5.11 Accessing FiberMINI Mirrors To service the optic, see Figure 57: The mirrors used in FiberMINI ® heads, 1. Remove the camera mount can be changed while the head is according to Section 5.9. mounted to the machine. 2.

  • Page 46: Right Angle Vision

    5.11.3 Right Angle Vision 5.11.4 Offset Vision To service the optic, see Figure 58: To service the optic, see Figure 59: 1. Remove the fixed mirror holder, 1. Remove the fixed mirror holder, beam bender and splitter cap camera mount and splitter cap according to Section 5.10.1,...

  • Page 47: Specifications

    Focal Point to Nozzle Adjustment ..................-4 mm to +9 mm Weight ............................1.5 to 4.0 kg LASER MECH COLLIMATOR Effective Focal Length (Doublet, Fused Silica) ........35 mm, 60 mm, 75 mm, 100 mm Collimating Lens (Diameter)......................28 mm Clear Aperture ...........................

  • Page 48: Recommended User-Serviceable Parts List

    7 Recommended User-Serviceable Parts List For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further assistance. ITEM PART # DESCRIPTION ALL VISION AND FIBER OPTIONS ELECTRICAL INTERFACE PLCAB0489...
  • Page 49 ITEM PART # DESCRIPTION ALL VISION AND FIBER OPTIONS STANDARD TIP RETAINER ASSEMBLY – HEIGHT SENSING PLORG0039 Gas Seal O-Ring (Included in PLTRA0449) PLORG0040 Engagement O-Ring (Included in PLTRA0449) PLTRA0449 Tip Retainer Assembly (Complete Height Sensing Assembly) PLTRA0321 Tip Retainer Nut Assembly (Included in PLTRA0449) STANDARD TIP RETAINER ASSEMBLY –...
  • Page 50 FIBER OPTIONS FIBER ADAPTER ASSEMBLIES PLFIA0001 Fiber Interface Assembly QBH PLFIA0003 Fiber Interface Assembly QD (LLK-D) PLFIA0006 Fiber Interface Assembly Q5 (LLK-B) LASER MECHANISMS’ SUPPLIED COLLIMATOR ASSEMBLIES Collimator 35mm – Complete Assembly PLFRA0084 Collimator 60 mm – Complete Assembly PLFRA0071 Collimator 75 mm –...
  • Page 51 Image A: Recommended Spare Parts for ALL OPTIONS Figure 60 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...
  • Page 52 Image B: Recommended Spare Parts for ALL VISION OPTIONS Figure 61 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...
  • Page 53 Image C: Recommended Spare Parts for ALL FIBER OPTIONS Figure 62 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...

  • Page 54: Troubleshooting

    8 Troubleshooting This height sensing unit is designed for robustness and simplicity with very little adjustment. Most height sensing problems can be attributed to electrical shorts between the tip and the body of the cutting head, or poor connections to the tip. Basic+ HSU Utility also provides helpful diagnostic information to identify faults. SYMPTOM CAUSE REMEDY...
  • Page 55 SYMPTOM CAUSE REMEDY Output is not stable, or Power supply to height sensor is Use a well-regulated DC power supply noisy noisy to provide proper voltage and current to height sensor unit. External source of noise is causing External sources of electrical or radio electrical interference frequency noise can interfere with the operation of the head.

  • Page 56: Appendix A - Interface Specifications

    9 Appendix A – Interface Specifications PLEBX0063 Example of Sourcing Outputs Example of Sinking Outputs From Motion Controller and From HSU from Motion Controller and From HSU Figure 63 FUNCTION DESCRIPTION +24VDC Power input (100mA) (18 to 30VDC) 0VDC Ground for all supplies (system common) FGND Chassis connection for Earth Ground FiberMINI ™...
  • Page 57 DESCRIPTION FUNCTION This is the difference between the reference voltage and HSU Analog Output voltage times a specified gain value. (Range +/-12V, <3mA) Ground for all supplies (system common) Reference voltage input (Range +/-10V, <1mA) Analog Input Used in calculating V Ground for all supplies (system common) This is a linearized or optimized voltage representing the measured tip-to-part standoff distance in millimeters.
  • Page 58 TB2 CONTINUED DESCRIPTION FUNCTION When active, this output indicates that the system is operating normally. The absence of this signal indicates a problem with the system and should be tied in conjunction with the motion inhibit READY Digital Output function of the controlled device. The Ready output signal will turn off when the ground voltage is above the set limit.

  • Page 59: Appendix B - Example Of Integrating The Hsu To A Plc/Cnc

    10 Appendix B – Example of Integrating the HSU to a PLC/CNC  Run/Hold In general, the HSU is intended to be very simple in design. The integration into a motion There are a couple of different ways of system requires a minimal amount of hardware implementing a Run/Hold request.
  • Page 60  Calculating the Standoff Error  Setting the Drive Command on Tip-Touch A simple calculation can be used to generate a standoff error signal that is assigned to the Drive In some instances it may be desirable to have Command. See Figure 67. This allows the Z- the Drive Command revert to constant value axis to track the surface of the part and maintain when Tip-Touch is active to move the Z-axis...

  • Page 61: Appendix C - Changing The Focal Length

    11 Appendix C – Changing the Focal Length Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent. Always wear powder free gloves or finger cots when handling optics and optic holders. 1.

  • Page 62: Appendix D - Configurations

    12 Appendix D – Configurations  Straight Fiber Input There are many possible configurations for the ® FiberMINI 2.0. To determine the components necessary for your configuration, see the assembly drawing supplied by Laser Mechanisms. The dimensions in this section are all millimeters and are for reference.
  • Page 63  A right angle fiber orientation can be configured in 90° increments. Figure 74  If your system requires an adapter clamp, it also requires a tilt style collimator (PLATP0015). Figure 75 Figure 73   Collimator: See Figure 76. Adapter Clamp: See Figure 74 and Figure 75.
  • Page 64   Crash Protection: See Figure 77. End Effector: See Figure 79. Mount Style Adapter Plate Type End Effector NOT Crash Protected Sensing PLTRA0449 PLADP0271 (Fixed Mount) Non-Sensing PLTRE0331 Crash Protected PLADP0261 Weld Cone PLTRE0338 Air Knife PLAKA0041 Figure 77 ...
  • Page 65   Adjustable Lens Holder Spacer: See Lens Manifold Block Spacer: See Figure Figure 80. Focal Length (mm) Spacer Tip Retainer Assembly Spacer Focal Length (mm) No Spacer 100 & 125 PLSBA0268 PLSBA0261 PLSBA0269 150 & 200 PLSBA0262 PLSBA0270 Figure 80 Figure 81 ...

  • Page 66: Appendix E - Service Dimensions

    13 Appendix E – Service Dimensions The dimensions in this section are all millimeters and are for reference during various service operations.  Adapter Mount Plate with Crash  Collimator and Beam Centering: See Protection: See Figure 83. Figure 82. Figure 82 Straight Right Angle...
  • Page 67   Adapter Mount Plate without Crash Cutting End Effector: See Figure 85. Protection: See Figure 84. Figure 85 Focal Length (mm) Spacer Spacer (mm) 113.4 None PLSBA0268 138.4 PLSBA0261 PLSBA0268 163.4 PLSBA0262 PLSBA0269 Figure 84 213.4 PLSBA0262 PLSBA0270 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV.
  • Page 68   Welding End Effector: See Figure 86. Air Knife End Effector: See Figure 87. Figure 86 Figure 87 Focal Focal Length Length (mm) Spacer Spacer (mm) (mm) Spacer Spacer (mm) (mm) 96.5 None PLSBA0268 121.5 PLSBA0261 PLSBA0268 146.5 PLSBA0262 PLSBA0269 166.0 145.5...
  • Page 69  Vision: See Figure 88. Figure 88 FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...

  • Page 70: Appendix F - Fiber End Styles

    14 Appendix F – Fiber End Styles Fiber End Type Sample Image HLC or QBH QD or LLK-D Q5 or LLK-B FiberMINI ™ 2.0 Operation Manual PLMNL0243 REV. A, Effective Date: 03/24/16...

  • Page 71: Glossary

    15 Glossary Assist Gas Height Sensing Unit Any gas that is applied to the working point coaxial with the focused beam on the material to assist the laser process. Pounds per Square Inch SHCS Cold Formed Nozzle Socket Head Cap Screw Cover Gas SHSS For welding applications only...
  • Page 72 Laser Mechanisms, Inc. 25325 Regency Drive • Novi, Michigan 48375 USA Phone: (248) 474-9480 • Fax: (248) 474-9277 In Europe: Phone: +32(0)92 18 70 70 • Fax: +32(0)92 18 70 79 Web: www.lasermech.com • E-Mail: info@lasermech.com...

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