Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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WF 25i LaserHybrid 6 kW UC
WF 25i LaserHybrid 4 kW UC
SB 360i LaserHybrid
Operating instructions
EN-US
42,0426,0291,EA 006-17122021
Table of contents
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 7
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Personal Protective Equipment 8
Danger from Toxic Gases and Vapors 8
Danger Posed by Shielding Gas Leak 8
Danger from Flying Sparks 9
Danger from Welding Current 9
Stray Welding Currents 9
EMC Measures 9
Particular Hazard Areas 10
Informal Safety Measures 11
Safety Measures at the Installation Location 11
Safety Measures in Normal Operation 12
Safety Inspection 12
Modifications 13
Spare and Wearing Parts 13
Calibrating Power Sources 13
The CE label 13
Copyright 13
EN-US
General information 15
General 17
General 17
Intended Use 17
Applications 17
Scope of Supply 18
Optional Components 18
Requirements 19
Mechanical Requirements 19
Robot Requirements 19
Ground Connection 19
Alignment 20
System Overview 21
System overview 21
Other LaserHybrid systems 22
Design Variants 24
Operating controls and connections 27
Product description 29
Product description 29
Product description SB 360i LaserHybrid 30
Connection Specifications 32
Connection specifications 32
Compressed air diagram 34
Pressure monitoring in the SplitBox SB 360i LaserHybrid 34
Commissioning 35
General 37
Safety 37
Setup Regulations 37
Grid Connection 37
Setting Up LaserHybrid Welding System 37
Installing the Laser Welding Head on the Robot 39
3
Mount Laser Welding Head on the Robot 39
Installing and Connecting SplitBox SB 360i LaserHybrid 40
Mounting the SplitBox SB 360i LaserHybrid on the robot 40
Connecting the SplitBox SB 360i LaserHybrid 42
Connecting the CrossJet and Additional Extraction 45
Connecting the CrossJet and Additional Extraction 45
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head 46
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head 46
Installing/Changing Wirefeed Rollers 47
Preparation 47
Installing/Replacing the Wirefeed Rollers 47
Final Tasks 48
Connecting the Laser Optics 49
Connecting the Laser Optics 49
Preparing Welding Torch 52
Equip Welding Torch 52
Place LaserHybrid hosepack on the robot 54
Placing the hosepack on the robot 54
Threading the Wire Electrode 56
Threading the Wire Electrode 56
Setting up Laser Welding Head 58
Stick Out 58
Adjustable axes 58
Adjustment device on the laser welding head 58
Adjusting the x axis 59
Adjusting the y axis 60
Set the radial airflow 61
Requirements 61
Setting the radial airflow 61
Creating Reference Program 64
Safety 64
General 64
Create a Reference Program 64
Signal Sequence for LaserHybrid Welding 66
Safety 66
Signal Sequence for LaserHybrid Welding 66
Measures before Starting Welding 68
Measures before Starting Welding 68
Operation Recommendations for LaserHybrid Welding System 69
Recommendations for the operation of a LaserHybrid welding system 69
Specifications for the compressed air supply 69
Maintenance 71
Replacing the Welding Torch and Welding Torch Wearing Parts 73
Safety 73
Welding Torch Spare Parts 73
Replacing the Welding Torch 73
Replacing welding torch wearing parts 74
Replace the spatter guard plate 76
Removing the Spatter Guard Plate 76
Mounting the Spatter Guard Plate 76
Replace the LaserHybrid UC hosepack 77
Removing the LaserHybrid UC Hosepack 77
Connect the LaserHybrid UC Hosepack 79
Replacing the Laser Optics 82
Safety 82
Disconnecting the fiber optic cable from the laser optics 82
Removing the Laser Optics 83
Assembly Positions for Installing the Laser Optics 86
Installing the laser optics 86
Checking Position of the Wire Electrode in relation to the Laser Focus 90
Safety 90
4
General 90
Checking Position of the Wire Electrode in relation to the Laser Focus 90
Example: Use of the Reference Program after Welding Torch Replacement 90
Measures to Reduce Contamination of the Optics 92
Measures to Reduce Contamination of the Optics 92
Appendix 95
Technical data 97
Laser welding head WF 25i LaserHybrid UC 97
LaserHybrid Hosepack MHP 360i LH-UC 97
SB 360i LH 98
EN-US
5
Safety Instructions
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.
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.
6
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 manufacturer 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.
EN-US
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
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.
7
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.
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 circumstances.
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
8
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
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.
EN-US
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
connections 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.
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
9
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
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.
10
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.
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).
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.
EN-US
Informal Safety
Measures
Safety Measures
at the Installation
Location
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.
All safety and danger notices on the LaserHybrid head must be kept in a legible state.
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.
11
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
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
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.
every 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
12
IEC (EN) 60 974-1 Equipment for Arc Welding, Part 1: Welding Current Sources
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.
EN-US
Spare and Wearing Parts
Calibrating Power
Sources
The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and Electro-
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.
magnetic Compatibility Directives and therefore has CE sign.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. 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.
13
14
General information
15
16
General
EN-US
General
The laser welding head WF 25i LaserHybrid UC is ideal for components with limited accessibility and is available in two
versions:
- WF 25i LaserHybrid 6 kW UC
Focal length of the laser optics =
300 mm
- WF 25i LaserHybrid 4 kW UC
Focal length of the laser optics =
200 mm
The WF 25i LaserHybrid UC is referred to
as the laser welding head for the rest of
these Operating Instructions.
Laser welding head WF 25i LaserHybrid 6 kW UC
with optional camera
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 UC is intended exclusively for automatic MIG/MAG welding in
combination 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 from the Operating Instructions for the individual components
- carrying out all the specified inspection and servicing work.
Applications The laser welding head is primarily used for MIG laser and MAG laser applications:
- in axle and bodywork production in the automotive industry for plate thicknesses of
1–4 mm
- in pipeline construction for plate thicknesses of 6–16 mm for the root pass
- in tank and boiler manufacturing.
17
Scope of Supply - 1 laser welding head WF 25i LaserHybrid UC (complete)
- 1 LaserHybrid UC hosepack
- 1 metal gauge to set the focal spot
- 1 flat spanner, size 8/10 mm
- 1 slotted screwdriver, 2.5 mm
- 1 Allen key, 2.5 mm
- 1 ballpoint Allen wrench, size 3 mm
- 1 ballpoint Allen wrench, size 4 mm
- 1 drive wheel spanner
- 1 stick out gauge
- 1 PushIn coupling connection
- 1 hose, 4x750 mm
- 1 flow volume meter up to 25 l/min
- 1 Operating Instructions
- Wirefeed accessories, depending on configuration
Optional Components
The following components are optional for the laser welding head WF 25i LaserHybrid
UC:
- Focus monitor
- Various laser beam sources
- Temperature sensor
- CrashBox
- Additional data line 3 x 0.5 mm²
18
Requirements
-
-
EN-US
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 approx. 7 kg. The optics weigh approx. an additional
2 kg. A mass of approx. 9 kg must be allowed for if the laser welding head is fully
equipped with optics and hosepack.
Therefore it must be possible for the robot axles to move a mass of 8 kg safely with the
accelerations specified.
The maximum resulting robot axle acceleration must not exceed 3 G (corresponds to approx. 30 m/s²).
Grounding cable with bifilar winding
Grounding cable coiled
19
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 work-
▶
piece surface when aligning the LaserHybrid head.
20
System Overview
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(11)
(10)
(8)
(9)
(12)
System overview LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the robot
(1) Welding wire drum *
(2) Unwinding wirefeeder:
WF 25i REEL 4R
+ OPT/i WF wire straightener (4,100,880,CK)
+ WF MOUNTING Drum
(3) Control line for unwinding wirefeeder
(4) Remote control
(5) Power source TPS 500i
+ robot interface **
+ cooling unit CU 1400i Pro MC or CU 2000i MC Single
+ upright bracket (screwed on)
(6) Wirefeeding hose
(7) Interconnecting hosepack
(8) Robot
(9) SplitBox SB 360i LaserHybrid
(10) LaserHybrid hosepack
(11) WF 25i LaserHybrid UC
(12) LaserHybrid cleaning station
EN-US
* As an alternative to the welding wire drum, the wirefeeding can also be carried
out via wirespools.
The following components are required for this purpose:
Unwinding wirefeeder WF 25i REEL 4R
+ OPT/i WF reel carriage D300
** for example: RI FB Inside/i or RI FB Pro/i
21
Other LaserHy-
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(11)
(10)
(8)
(9)
(12)
brid systems
LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the wall
(3) Wirefeeding hose
(4) Interconnecting hosepack
(5) Robot
(6) SplitBox SB 360i LaserHybrid
(7) LaserHybrid hosepack
(8) WF 25i LaserHybrid UC
(9) LaserHybrid cleaning station
(10) Welding wire drum
(11) Unwinding wirefeeder:
WF 25i REEL 4R
+ OPT/i WF wire straightener (4,100,880,CK)
+ WF MOUNTING Wall
(12) Control line for unwinding wirefeeder
(13) Remote control
(14) Power source TPS 500i
+ robot interface
+ cooling unit CU 1400i Pro MC or CU 2000i MC Single
+ upright bracket (screwed on)
22
LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the power
(5)
(6)
(2)
(1)
(3)
(8)
(10)
(7)
(9)
(4)
(11)
source
(1) Remote control
(2) Control line for unwinding wirefeeder
(3) Power source TPS 500i
+ robot interface
+ cooling unit CU 1400i Pro MC or CU 2000i MC Single
+ upright bracket (screwed on)
+ interconnecting hosepack
(4) SplitBox SB 360i LaserHybrid
(5) Wirespool D300
(6) Unwinding wirefeeder:
WF 25i REEL 4R
+ OPT/i WF Reel carriage D300
(7) LaserHybrid hosepack
(8) Wirefeeding hose
(9) Robot
(10) WF 25i LaserHybrid 6 kW UC
(11) LaserHybrid cleaning station
EN-US
23
Design Variants
Power source is in the 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 300i LH W/7.5 m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – unwinding wirefeeder
- WF MOUNTING Drum
- Wirefeeding hose L=10 m
- Laser welding head
Application:
The robot only makes slight compensatory movements.
Robot axles seven and eight carry out the majority of the welding feed movement.
Example:
Circumferential weld on boilers, axles, etc.
Power source is in the 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 300i LH W/7.5 m – LaserHybrid hosepack
- Wirespool
- WF 25i REEL 4R – unwinding wirefeeder
- WF reel carriage D300
- Wirefeeding hose L=10 m
- Laser welding head
Application:
Only for test systems (wirespool is not used in series production)
Power source is not in the 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 on the wall
- MHP 300i LH W/4.2 m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – unwinding wirefeeder
- WF MOUNTING Drum
- Wirefeeding hose L=20 m
- Laser welding head
Application:
Robot axles 1–6 carry out the welding feed movement.
Example:
Longitudinal seam on boilers, battery trays, etc.
24
Power source is not in the welding cell (II)
- TPS 500i – power source
- HP 95i CON W/10 m/95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, wall mounting
- MHP 300i LH W/7.5 m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – unwinding wirefeeder
- WF MOUNTING Drum
- Wirefeeding hose L=20 m
- Laser welding head
Application:
Robot axles 1–6 carry out the welding feed movement.
Example:
Longitudinal seam on boilers, battery trays, etc.
Power source is on a gantry and moves at the same time
- TPS 500i – power source
- HP 95i CON W/10 m/95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the gantry
- MHP 300i LH W/4.2 m or 7.5 m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – unwinding wirefeeder
- WF MOUNTING Drum
- Wirefeeding hose L=20 m
- Laser welding head
EN-US
Application:
Robot axles 1–8 carry out the welding feed movement.
Example:
Longitudinal seam in rail vehicle manufacturing, etc.
25
26
Operating controls and connections
27
28
Product description
(2)
(1)
(3)
(5)
(6)
(7)
(8)
(10)
(17)
(16)
(15)
(14)
(11)
(12)
(13)
(4)
(3a)
(9)
Product description
EN-US
Item Name
(1) CrossJet exhaust air connection
(2) Protective cover/fiber optic cable connection
(3) Additional extraction tube
(3a)
Optional additional extraction tube
with matching spatter guard plate
Depending on the configuration, one of the two extraction tubes is fitted on deliv-
ery.
(4) Camera (option)
(5) Laser optics
(6) Radial air flow
(7) Gas nozzle
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(8) LaserHybrid welding torch
(a)
(b)
(c)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(14)
(13)
(12)
(11)
(9)
(8)
(10)
(9) Adjustment device
(10) Wirefeeder roller cover
(11) Motor cover
(12) Control box
(13) Robot connection bracket
The controls are located on the opposite robot connection bracket:
a) Wire-return button
b) Wire-threading button
c) Gas-test button
Product description SB 360i
LaserHybrid
(14) Robot support
(15) CrashBox (option)
(16) Laser optics water cooling connection
(17) LaserHybrid UC hosepack
30
Back
Item Name
(1) (+) Current socket with fine thread
(2) Shielding gas connection socket
For connecting the power cable from the interconnecting hosepack
Front
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