Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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WF 25i LaserHybrid 10 kW
SB 360i LaserHybrid
Operating Instructions
LaserHybrid
EN-US
[
42,0426,0279,EN 010-19032020
2
Table of contents
Safety Instructions ..................................................................................................................................... 7
Explanation of Safety Instructions......................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 8
Environmental Conditions..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Personal Protective Equipment............................................................................................................. 9
Danger from Toxic Gases and Vapors.................................................................................................. 9
Danger Posed by Shielding Gas Leak.................................................................................................. 9
Danger from Flying Sparks ................................................................................................................... 10
Danger from Welding Current ............................................................................................................... 10
Stray Welding Currents......................................................................................................................... 10
EMC Measures ..................................................................................................................................... 10
Particular Hazard Areas........................................................................................................................ 11
Informal Safety Measures..................................................................................................................... 12
Safety Measures at the Installation Location ........................................................................................ 13
Safety Measures in Normal Operation.................................................................................................. 13
Safety Inspection .................................................................................................................................. 13
Modifications ......................................................................................................................................... 14
Spare and Wearing Parts...................................................................................................................... 14
Calibrating Power Sources ................................................................................................................... 14
The CE label ......................................................................................................................................... 14
Copyright............................................................................................................................................... 14
EN-US
General Information 15
General ...................................................................................................................................................... 17
General ................................................................................................................................................. 17
Intended Use......................................................................................................................................... 17
Applications........................................................................................................................................... 17
Scope of Supply.................................................................................................................................... 18
Optional Components ........................................................................................................................... 19
Gas nozzle cross jet.............................................................................................................................. 19
Requirements............................................................................................................................................. 20
Mechanical Requirements .................................................................................................................... 20
Robot Requirements ............................................................................................................................. 20
Ground Connection............................................................................................................................... 20
Alignment .............................................................................................................................................. 21
System Overview ....................................................................................................................................... 22
System Overview .................................................................................................................................. 22
Other LaserHybrid Systems.................................................................................................................. 23
Setup Variants ...................................................................................................................................... 25
Operating controls and connections 27
Product description .................................................................................................................................... 29
Device Description WF 25i LaserHybrid 10 kW .................................................................................... 29
Device Description, SB 360i LaserHybrid ............................................................................................. 30
Collision Protection .................................................................................................................................... 32
General ................................................................................................................................................. 32
Safety.................................................................................................................................................... 32
Checking the Reference Point after a Collision .................................................................................... 32
Signal Analysis...................................................................................................................................... 32
Connection Specifications.......................................................................................................................... 33
Connection Specifications..................................................................................................................... 33
Compressed Air Diagram...................................................................................................................... 35
Pressure Monitoring in the SplitBox SB 360i LaserHybrid.................................................................... 35
3
Commissioning 37
General ...................................................................................................................................................... 39
Safety.................................................................................................................................................... 39
Setup Regulations................................................................................................................................. 39
Grid Connection .................................................................................................................................... 39
Set Up LaserHybrid Welding System.................................................................................................... 40
Installing the Laser Welding Head on the Robot........................................................................................ 41
Connection Options on the Robot......................................................................................................... 41
Installing the Laser Welding Head on the Robot................................................................................... 41
Installing and Connecting SplitBox SB 360i LaserHybrid .......................................................................... 42
Installing SplitBox SB 360i LaserHybrid on Robot................................................................................ 42
Connecting SplitBox SB 360i LaserHybrid............................................................................................ 44
Connecting Crossjet................................................................................................................................... 46
Connecting the CrossJet....................................................................................................................... 46
Connecting LaserHybrid Hosepack to Laser Welding Head...................................................................... 48
Connecting LaserHybrid Hosepack to Laser Welding Head................................................................. 48
Connecting/changing Wirefeeding Hose to/on Laser Welding Head.................................................... 49
Installing/Changing Wirefeed Rollers......................................................................................................... 50
Installing/Changing Wirefeed Rollers.................................................................................................... 50
Connecting Laser Optics and Extra Extraction .......................................................................................... 51
Connecting Laser Optics....................................................................................................................... 51
Connecting Extra Extraction ................................................................................................................. 54
Preparing Welding Torch ........................................................................................................................... 57
Preparing Welding Torch ...................................................................................................................... 57
Installing Hosepack on Robot .................................................................................................................... 59
Placing the Hosepack on the Robot...................................................................................................... 59
Threading the Wire Electrode .................................................................................................................... 61
Threading the Wire Electrode ............................................................................................................... 61
Setting up Laser Welding Head ................................................................................................................. 62
Stick Out ............................................................................................................................................... 62
Adjustable Axes .................................................................................................................................... 63
Adjustment Mechanisms on the Laser Welding Head .......................................................................... 64
Setting Up X-Axis.................................................................................................................................. 65
Setting Up Y-Axis.................................................................................................................................. 66
Setting Up Z-Axis .................................................................................................................................. 67
Creating Reference Program ..................................................................................................................... 68
Safety.................................................................................................................................................... 68
General ................................................................................................................................................. 68
Creating Reference Program ................................................................................................................ 68
Signal Sequence for LaserHybrid Welding ................................................................................................ 70
Safety.................................................................................................................................................... 70
Signal Sequence for LaserHybrid Welding ........................................................................................... 70
Measures before Starting Welding............................................................................................................. 72
Measures before Starting Welding........................................................................................................ 72
Operation Recommendations for LaserHybrid Welding System................................................................ 73
Operation Recommendations for LaserHybrid Welding System........................................................... 73
Specifications for the compressed-air supply ....................................................................................... 73
Maintenance 75
Replacing the Welding Torch and Welding Torch Wearing Parts.............................................................. 77
Safety.................................................................................................................................................... 77
Welding Torch Spare Parts................................................................................................................... 77
Replacing the Welding Torch................................................................................................................ 77
Replacing Welding Torch Wearing Parts .............................................................................................. 79
Replacing the Spatter Guard Plate and Extra Extraction........................................................................... 80
Replacing the Spatter Guard Plate ....................................................................................................... 80
Replacing the Extra Extraction.............................................................................................................. 80
Replacing the Laser Optics........................................................................................................................ 81
Safety.................................................................................................................................................... 81
Replacing the Trumpf Laser Optics ...................................................................................................... 81
Preparation ........................................................................................................................................... 81
4
Removing the Laser Optics................................................................................................................... 84
Inserting the Laser Optics..................................................................................................................... 86
Checking/Adjusting Laser Optics Focus ............................................................................................... 89
Fixing the Laser Optics ......................................................................................................................... 91
Final Tasks............................................................................................................................................ 92
Laser Optics – Overview....................................................................................................................... 94
Checking Position of the Wire Electrode in relation to the Laser Focus .................................................... 95
Safety.................................................................................................................................................... 95
General ................................................................................................................................................. 95
Checking Position of the Wire Electrode in relation to the Laser Focus ............................................... 95
Example: Reference Program Application after Welding Torch Change.............................................. 96
Measures to Reduce Contamination of the Optics .................................................................................... 97
Measures to Reduce Contamination of the Optics ............................................................................... 97
Appendix 99
Technical Data ........................................................................................................................................... 101
WF 25i LaserHybrid 10 kW (laser welding head).................................................................................. 101
LaserHybrid hosepack MHP 360i LH.................................................................................................... 101
EN-US
5
6
Safety Instructions
EN-US
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The LaserHybrid head has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however, it can
cause
- injury or death to the operator or a third party,
- damage to the LaserHybrid head and other material assets belonging to the operating
company,
- inefficient operation 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 Instructions must always be at hand wherever the LaserHybrid head is being used. In addition to the Operating Instructions, all applicable local rules and regulations
regarding accident prevention and environmental protection must also be followed.
All safety instructions and warning signs on the LaserHybrid head itself must:
- be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over.
7
For the location of the safety and danger notices on the LaserHybrid head, refer to the section headed "General" in the Operating Instructions for the LaserHybrid head.
Before switching it on, resolve any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, CrNi
and steel materials.
Any other use does not constitute proper use.
The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work.
Never use the LaserHybrid head or the power source to thaw pipes.
The LaserHybrid head is designed for operation in industry and business. The manufac-
turer shall not be liable for any damage resulting from use in a living area.
The manufacturer shall not be liable for faulty or incorrect work results either.
Environmental
Conditions
Obligations of the
Operating Company
Operation or storage of the LaserHybrid head outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer is not responsible for
any damage resulting from improper 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.)
The operating company must only allow persons to work with the LaserHybrid head if they
- are familiar with the basic occupational safety and accident prevention regulations and
are trained in handling the LaserHybrid head
- have read and understood these Operating Instructions, especially the section "Safety
Rules," and have confirmed this with their signature
- are trained according to the requirements for the work results.
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
8
All persons who are assigned to work with the LaserHybrid head must do the following before beginning work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
Personal Protective Equipment
Please take the following precautions for your own personal safety:
Persons present in the sealed cell for the LaserHybrid process must
- wear rigid, wet-insulating footwear
- protect hands with appropriate gloves (featuring electrical insulation and thermal protection)
- protect their eyes from laser beams by wearing regulation-compliant safety glasses for
lasers. To protect their face and eyes against UV beams, further protection in the form
of a protective shield with regulation-compliant filter insert for laser protection class 4
must also be used in front of the safety glasses for lasers and the person's face. Do
not look into the laser beam, even with a regulation-compliant filter insert for laser protection class 4.
- Only wear suitable (flame-resistant) clothing
- Wear hearing protection designed for crossjet noise (120 dbA)
If there are persons present in the sealed cell for the LaserHybrid process,
- inform them of all the dangers that may be posed during operation (e.g. potential accumulation of gases hazardous to health, risk of asphyxiation due to lack of oxygen in
the breathable air, hazards posed by laser light, etc.)
- provide protective equipment
- construct protective walls or install protective curtains.
EN-US
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 work area using appropriate equipment.
Ensure that there is sufficient fresh air.
Use breathing apparatus with air supply if there is insufficient ventilation.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
Danger Posed by
Shielding Gas
Leak
Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Keep flammable vapors (such as solvent vapors) out of the laser and arc radiation range.
Risk of asphyxiation due to uncontrolled shielding gas leak
9
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in
the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least
20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylinder
or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the
main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.
Danger from Flying Sparks
Danger from
Welding Current
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (35 ft.) from the LaserHybrid welding
process or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums,
or pipes if these have not been prepared in accordance with corresponding national and
international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/
were stored. Residues pose a risk of explosion.
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 con-
nections and scorched cables immediately.
Stray Welding
Currents
EMC Measures WARNING! Electromagnetic field! Electromagnetic fields may cause health problems
If the following instructions are not observed, stray welding currents may occur, which can
result in the destruction of ground conductors, the power source used, the LaserHybrid
head, and other electrical equipment.
Ensure that the workpiece terminal is securely connected to the workpiece. If the floor is
electrically conductive, set up the power source so that it is insulated wherever possible.
that are not yet known.
The operator is responsible for ensuring that there is no electromagnetic interference with
electrical and electronic equipment.
If electromagnetic interference is discovered, the operator is obliged to take action to rectify
the situation.
10
Check and evaluate possible problems and the interference immunity of equipment in the
vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
- The health of persons close by, e.g., those with pacemakers and hearing aids
Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of where the welding work is taking place.
Supporting measures to avoid EMC problems:
a) Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
b) Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMC problems)
- Route them far from other lines
c) Equipotential bonding
d) Workpiece grounding
- If necessary, establish grounding using suitable capacitors
e) Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EN-US
Particular Hazard
Areas
Laser beam poses a risk of injury to the eyes. In addition to using the protective shield with
a regulation-compliant UV filter insert, eyes should be protected from laser beams using
regulation-compliant safety glasses for lasers. It must still be ensured, however, that no
one can accidentally look into the laser beam.
If the workpiece surface is especially bright 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 drive or into rotating drive
parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted properly.
- Keep all covers and side parts closed.
Welding wire from the welding torch poses a high risk of injury (cuts to the hand, injuries to
the face and eyes, etc.).
For this reason, always hold the welding torch away from your body (devices with wirefeeder) and wear suitable protective goggles.
Do not touch workpieces during or after welding – risk of burns.
11
Slag may fly off from workpieces that are cooling down. For this reason, be sure to wear
regulation-compliant protective equipment and ensure that other people are sufficiently
protected even when reworking workpieces.
Leave the welding torch and other parts with a high operating temperature to cool before
working on them.
Special regulations apply in areas where there is a risk of fire or explosion
– observe relevant national and international regulations.
Power sources for work in spaces where electrical hazards pose a greater risk (e.g. the
boiler room) must be marked with a (Safety) sign. The power source should not be located
in these types of spaces, however.
Risk of scalding due to coolant leakage. Before disconnecting connections for the coolant
supply hose or return connection, switch off the cooling unit.
When handling coolants, observe the specifications on the safety data sheet. The coolant
safety data sheet is available from your service center or from the manufacturer's homepage.
Only use suitable load-carrying equipment from the manufacturer for transporting devices
by crane.
- Attach chains or ropes to all designated suspension points on suitable load-carrying
equipment.
- Chains or ropes must be as close to perpendicular as possible.
- Remove the gas cylinder and wirefeeder (MIG/MAG and TIG devices).
Informal Safety
Measures
Always use a suitable wirefeeder hoisting attachment with insulation on the crane for hoisting the wirefeeder (MIG/MAG and TIG devices).
If the device is fitted with a carrier belt or handle, this should be used exclusively for transportation by hand. The carrier belt is not suitable for transportation by crane, counterbalanced lift truck or other mechanical chain hoists.
All lifting equipment (belts, straps, chains, etc.) used in 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 connection. Use suitable Teflon tape to seal the thread of the
shielding gas connection adapter on the device side before installation.
The Operating Instructions must always be at hand wherever the LaserHybrid head is being used.
In addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be made available and be followed.
12
All safety and danger notices on the LaserHybrid head must be kept in a legible state.
Safety Measures
at the Installation
Location
The cell for the LaserHybrid welding process must meet the following requirements:
- be light-proof in relation to surrounding rooms
- is shielded with at least 1 mm steel plate and/or approved laser protective glass to protect against UV and laser beams
- The laser welding process and the arc welding process must be stopped automatically
and immediately as soon as the cell is opened.
A toppling device can be deadly! Set up the device securely on an even, solid surface
- A tilt angle of no more than 10° is permitted
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure an all-round clearance of 0.5 m (1 ft. 7.69 in.) so that
the cooling air can enter and leave unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Before transporting the device, always completely drain the coolant and dismantle the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
EN-US
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before it is commissioned. Have any damage repaired by trained service technicians before commissioning the device.
Safety Measures
in Normal Operation
Safety Inspection The operator is required to have the LaserHybrid head tested by an electrician after every
Only operate the LaserHybrid head if all protective and safety devices are fully functional.
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 company,
- inefficient operation of the device.
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before conditioning the LaserHybrid head, ensure that no one can be put in danger.
The LaserHybrid head must be examined at least once a week for externally detectable
damage and functionality of the safety devices.
alteration, installation or modification, and all repairs and maintenance, and at least every
12 months, to ensure that it is in its correct state.
Regulation Title
IEC (EN) 60 974-1 Equipment for Arc Welding, Part 1: Welding Current Sources
13
BGV A2, Section 5 Electrical Plants and Equipment
BGV D1, Sections 33 / 49Welding, Cutting and Related Work Methods
VDE 0701-1 Repairing, Modifying and Testing Electrical Devices;
General Requirements
VDE 0702-1 Repeating Tests on Electrical Devices
Modifications Do not carry out any alterations, installations, or modifications to the LaserHybrid head
without first obtaining the manufacturer’s permission.
Parts that are not in perfect condition must be replaced immediately.
Spare and Wearing Parts
Calibrating Power
Sources
The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and Electromag-
Copyright Copyright of these operating instructions remains with the manufacturer.
Use only original spare and wearing parts (also applies to standard parts).
It is impossible to guarantee that externally procured parts are designed and manufactured
to meet the demands made on them, or that they satisfy safety requirements.
When ordering, specify the exact name and part number according to the Spare Parts List
as well as the serial number of your device.
Regular calibration of power sources is required in accordance with international standards. The manufacturer recommends a calibration interval of 12 months. Please contact
your service center if you require further details.
netic Compatibility Directives and therefore has CE sign.
Text and illustrations are technically correct at the time of going to print. The right to make
modifications is reserved. The contents of the operating instructions shall not provide the
basis for any claims whatsoever on the part of the purchaser. If you have any suggestions
for improvement, or can point out any mistakes that you have found in the operating instructions, we will be most grateful for your comments.
14
General Information
General
EN-US
General
The laser welding head combines the benefits of a laser beam with the benefits of the
MIG/MAG welding process.
For the LaserHybrid process this results in
a high penetration depth, a narrow heat-affected zone, filler metal and good gap bridging.
Additional benefits of the laser welding head:
- high welding speed and great cost-effectiveness
- high process stability combined with a low level of rejects and reworking effort
- high quality weld seam
- low heat input, reduced distortion
- high availability of the welding system, high service life of the wearing parts
- flexible use
- high gap tolerance
- adaptation for fiber, disk, and diode laser possible.
Intended Use The WF 25i LaserHybrid 10 kW is designed exclusively for automated MIG/MAG welding
in connection with Fronius system components.
Any other use does not constitute proper use.
The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
- Following all the instructions in these operating instructions for the individual components
- Carrying out all the specified inspection and servicing work
The WF 25i LaserHybrid 10 kW will be referred to as the "laser welding head" in the rest
of these Operating Instructions.
Applications The WF 25i LaserHybrid 10 kW welding head is used for the following applications:
- In the manufacturing of axles and bodies in the automotive industry, to make sheets
of 1–4 mm in thickness
- In rail vehicle manufacturing, for longitudinal seams and lap joints
- In shipbuilding, for butt welds
- In vehicle manufacturing, for lap joints and to weld wheel rims
- In container construction, for lap joints, circumferential welds and butt welds
- For corner joints on hoists
17
Scope of Supply The following components are included as standard with the laser welding head:
- 1 x WF 25i LaserHybrid 10 kW laser welding head (complete)
- 1 x LaserHybrid hosepack
- 1 x stick out gauge
- 1 x flow volume meter (max. 25 l/min)
- 1 x Operating Instructions
- Tool and wirefeed end accessories, depending on the configuration
Tool and Wirefeeder Accessories:
Description No.
Extractor tool for register pins
44,0450,1223
Gauge for adjusting the focal spot
42,0201,1216
Stick out gauge
42,0201,1742
Allen key, size 6 mm (for adjusting the position on the holder unit)
42,0435,0001
Allen key, size 5 mm (for adjusting the position on the holder unit)
42,0410,0014
Allen key, size 4 mm (for adjusting the position on the holder unit)
42,0410,0013
Allen key, size 3 mm (for fixing the extraction hose)
42,0410,0012
Allen key, size 2.5 mm (for adjusting the laser optics)
42,0435,0002
Trimming aid for inner liners
42,0001,4936
Spanner for welding torch coupling and hosepack coupling
45,0200,1404
Flat spanner, wrench size 12 mm
42,0410,0007
Flat spanner, wrench size 8/10 mm
42,0410,0004
Drive wheel key
42,0200,9344
1
1
1
1
1
1
1
1
1
1
1
1
1
18
Optional Components
Possible laser optics:
- Trumpf BEO D70
- Precitec YW52
- Highyag BIMO
The following components are optional for the WF 25i LaserHybrid 10 kW laser welding
head:
- Focus monitoring
- Temperature sensor
- Pressure sensor crossjet
- Extraction hose set
- Mounting plate 17.5 mm
- Gas nozzle crossjet
EN-US
Gas nozzle cross
jet
During welding, depending on the energy density and material, the laser triggers a plasma
flare of a varying height which absorbs the laser light.
At constant laser output a penetration of different depths is created.
To ensure constant penetration despite the plasma flare, it is possible to use the gas nozzle
cross jet.
The gas nozzle cross jet uses compressed air to generate a fine current of air that cuts off
the plasma flare at a defined height.
IMPORTANT!
- Because the gas nozzle cross jet is situated very closely to the opening of the gas outlet this can result in swirling gas and subsequently: pores.
- Furthermore, if the air current experiences resistance this can lead to acute pore formation.
- The plasma flare contains welding spatter and welding fume. If the plasma flare is
blown out, the surrounding area will be severely polluted.
Scope of Application:
- For freely accessible components
- For a laser output of at least 4 kW
- Mainly for butt welds with a full penetration root pass or where precise welding penetration depth is required
19
Requirements
-
Mechanical Requirements
Robot Requirements
Ground Connection
The following mechanical requirements must be met in order to ensure a stable and repeatable LaserHybrid process:
- Accurate welding torch guidance for robots or single-purpose machines (e.g. longitudinal chassis)
- Precise weld seam preparation
- Low component tolerances
- Precise and very fast weld seam management systems with little deviation
The laser welding head weighs around 19 kg. The optics weigh a further 3 kg approximately. 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 acceleration for the laser welding head is 3 g at 5–
150 Hz, based on use of the laser optics.
-
Grounding cable with bifilar winding Grounding cable coiled
20
Alignment
y
5°
Example: Work angle 5° leading
CAUTION!
Danger 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 workpie-
ce surface when aligning the LaserHybrid head.
EN-US
21
System Overview
System Overview LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Robot
(6)
(10)
(4)
(2)
(3)
(1)
(1) Welding wire drum *
(2) Wirefeeder reel:
WF 25i REEL 4R
+ OPT/i WF Wire straightening
path (4,100,880,CK)
+ WF MOUNTING Drum
(3) Control line for wirefeeder reel
(4) Remote control
(5) Power source TPS 500i
+ robot interface **
+ Cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ Upright bracket (screwed in
place)
(5)
(11)
(8)
(7)
(9)
(6) Wirefeeding hose
(7) Interconnecting hosepack
(8) Robot
(9) SplitBox SB 360i LaserHybrid
(10) Hosepack LaserHybrid
(11) WF 25i LaserHybrid 10 kW
(12) Cleaning station LaserHybrid
(12)
22
* The wire can also be fed via a wirespool (alternative to welding wire drum).
The following components are required for this:
Wirefeeder reel WF 25i REEL 4R
+ OPT/i WF reel carriage D300
** Example: RI FB Inside/i or RI FB Pro/i
Other LaserHybrid Systems
LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Wall
(6)
(9)
(10)
EN-US
(2)
(4)
(5)
(3)
(1)
(1) Welding wire drum
(2) Wirefeeder reel:
WF 25i REEL 4R
+ OPT/i WF Wire straightening
path (4,100,880,CK)
+ WF MOUNTING Wall
(3) Control line for wirefeeder reel
(4) Remote control
(5) Power source TPS 500i
+ Robot interface
+ Cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ Upright bracket (screwed in
place)
(7)
(11)
(8)
(12)
(6) Wirefeeding hose
(7) Interconnecting hosepack
(8) Robot
(9) SplitBox SB 360i LaserHybrid
(10) Hosepack LaserHybrid
(11) WF 25i LaserHybrid 10 kW
(12) Cleaning station LaserHybrid
23
LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Power
(5)
(6)
(2)
(1)
(3)
(8)
(10)
(7)
(9)
(4)
(11)
Source
(1) Remote control
(2) Control line for wirefeeder reel
(3) Power source TPS 500i
+ Robot interface
+ Cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ Upright bracket (screwed in
place)
+ Interconnecting hosepack
(4) SplitBox SB 360i LaserHybrid
(5) Wirespool D300
(6) Wirefeeder reel:
WF 25i REEL 4R
+ OPT/i WF reel carriage D300
(7) Hosepack LaserHybrid
(8) Wirefeeding hose
(9) Robot
(10) WF 25i LaserHybrid 10 kW
(11) Cleaning station LaserHybrid
24
Setup Variants
Power Source Located in Welding Cell (I)
- TPS 500i – power source
- HP 95i CON W / 1.2 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the power source
- MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 10 m
- Laser welding head
Area of application:
The robot only makes minor compensatory movements.
Robot axles 7 and 8 carry out the majority of the welding feed movements.
Example:
Circumferential welds on boilers, axles, etc.
Power Source Located in Welding Cell (II)
- TPS 500i – power source
- HP 95i CON W / 1.2 m / 95 mm² – 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 – wirefeeder reel
- WF reel carriage D300
- Wirefeeding hose L = 10 m
- Laser welding head
EN-US
Area of application:
For test systems only (no wirespool in series production)
Power Source Not Located in Welding Cell (I)
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the robot or the wall
- MHP 360i LH/W/FSC/FW 4.2m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application:
Robot axles 1–6 carry out the welding feed movements.
Example:
Longitudinal seams on boilers, battery trays, etc.
25
Power Source Not Located in Welding Cell (II)
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, wall mounting
- MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application:
Robot axles 1–6 carry out the welding feed movements.
Example:
Longitudinal seams on boilers, battery trays, etc.
Power Source Is on a Gantry and Moves Too
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on gantry
- MHP 360i LH/W/FSC/FW 4.2 m or 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application:
Robot axles 1–8 carry out the welding feed movements.
Example:
Longitudinal seams in rail vehicle construction, large base frames (e.g. press brakes),
etc.
26
Operating controls and connections
Product description
EN-US
Device Description WF 25i LaserHybrid 10 kW
(1)
(2)
(3)
(4)
(6)
(8)
(9)
(10)
(11)
(2)
(3)
(5)
(7)
(15)
(16)
(17)
(18)
(19)
(20)
(12)
(13)
(14)
Item Description
(1) Exhaust for crossjet (must be connected to an extraction unit)
(2) Supply to crossjet
(3) Connection for optional pressure monitoring
A LaserHybrid hosepack with extra data line is needed for optional pressure monitoring.
Pressure is monitored in SplitBox SB 360i LaserHybrid (see page 35) for the laser
welding head and LaserHybrid hosepack.
(4) Supply to radial fan flow
(5) Supply to gas nozzle crossjet
(6) Fiber optic cable
(7) LaserHybrid hosepack connection
(8) Control box
(9) Drive unit cover
(21)
29
Item Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(14)
(13)
(12)
(11)
(9)
(8)
(10)
(10) Gas-test button
Wire-return button*
Wire-threading button*
* The wire-return and wire-threading buttons are located on the opposite side of the
laser welding head.
(11) Mounting plate
Thickness 21 mm or 17.5 mm, depending on application
(12) LaserHybrid welding torch
(13) Gas nozzle crossjet (optional)
(14) Gas nozzle
(15) Robot holder
(16) Bracket for robot connection
(17) Laser optics
(18) Extra extraction
(19) Laser optics water cooling connections
(20) Connection to radial air stream
(21) Crossjet
Device Description, SB 360i LaserHybrid
30
Back Front
Item Description
(1) (+) Current socket with fine thread
for connecting the power cable from the interconnecting hosepack
(2) Shielding gas connection socket
(3) SpeedNet connection
for connecting the SpeedNet cable from the interconnecting hosepack
(4) SpeedNet connection
(5) Gas purging connection
(6) Connection for welding torch cooling – coolant return flow (red)
for connecting system add-ons e.g. the remote control
for connecting the coolant return flow hose from the interconnecting hosepack
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