BOCI BLT641 - User Manual

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Summary

Product Description

Product View and Components

Detailed diagram of the cutting head's structure and interface components.

Technical Specifications

Key technical specifications including laser power, fiber interface, and operating conditions.

LED Indicator Meanings

Explanation of LED indicators for Power, Run, Link, and Sensor states.

Gas Interface

Gas Interface Connections and Quality Requirements

Details on cutting gas and nozzle cooling gas connections, and required gas quality standards.

Water Cooling Interface

Water Cooling Connection and Settings

Instructions for connecting water cooling and recommended settings for pressure and flow rate.

Electrical Interface

Electrical Interface Waterproof Precautions

Safety guidelines for PWE and aviation plug interfaces to maintain IP64 protection.

Bus System Wiring Diagram

Diagram illustrating the wiring connections for the bus system, including BCS210E.

Non-Bus System Wiring Diagram

Wiring diagram for non-bus systems, showing connections to BCL4500A and BCS100.

Cutting Head Installation

Installation Preparation Steps

Required objects and preparations for cutting head installation, including clean workbench and cleaning kit.

Detailed Installation Operation Process

Detailed steps for specific operation processes during cutting head installation.

Clean Bench Preparation Procedure

Steps to prepare and ensure the functionality of the clean bench before installation.

Placing Cutting Head in Clean Workbench

Procedure for horizontally placing the cutting head inside the clean workbench.

Cleaning the Fiber Interface

Instructions for cleaning and wiping the fiber interface of the cutting head with ethanol.

Checking Laser Fiber End Face

Procedure to inspect the laser fiber end face for pollution using a flashlight.

Removing Protective Film and Cap

Steps to remove the protective film or cap from the optical fiber interface.

Inserting the Laser Fiber Interface

Guidance on aligning and inserting the laser fiber optic plug into the cutting head port.

Wrapping and Sealing the Interface

Procedure for wrapping and sealing the interface between the optical fiber and cutting head.

Mounting Cutting Head on Backplane

Steps to mount the cutting head onto the machine tool's Z-axis backplane using screws.

Installing Ceramic Body and Nozzle

Instructions for installing the ceramic body, locking ring, and nozzle onto the cutting head.

Beam Centering Operation

Procedure for adjusting the XY centering knob to align the laser beam with the nozzle center.

Appendix A - Maintenance

Maintenance Schematic Diagram of Product Structure

Detailed schematic diagram of the cutting head structure, highlighting components relevant to maintenance.

Replacing the Upper Protective Lens

Step-by-step guide for replacing the upper protective lens of the cutting head.

Replacing the Lower Protective Lens

Step-by-step guide for replacing the lower protective lens of the cutting head.

Appendix B - Mechanical Dimensions

Cutting Head Installation Dimensions

Diagram showing the installation dimensions and key measurements of the cutting head.

The BLT641 is an intelligent cutting head designed for laser cutting applications, manufactured by BOCI (Brilliant Optical Cutting Instrument). This manual provides comprehensive information regarding its product parameters, installation, usage, and maintenance.

Function Description

The BLT641 cutting head is primarily used for laser cutting, integrating various components to deliver a precise and efficient cutting process. It features an optical fiber interface for laser input, a collimation unit, and a focusing unit to shape and direct the laser beam. The device also includes protective lenses to safeguard the internal optics, a ceramic body, and a nozzle for gas delivery and beam shaping at the cutting point. Its design incorporates a sophisticated electrical interface, supporting both bus and non-bus systems, and a water-cooling system to maintain optimal operating temperatures. The cutting head is equipped with LED indicators to provide real-time status updates on power, motor operation, system communication, and sensor readings, ensuring operators can quickly identify and address any issues.

Important Technical Specifications

The BLT641 cutting head boasts robust technical specifications suitable for high-power laser cutting:

Laser Wavelength: 1030-1090nm, compatible with common fiber lasers.
Laser Power: Up to 15KW, indicating its capability for heavy-duty industrial applications.
Fiber Interface: Supports QBH, QD, Q+, and ADD types, offering versatility in fiber optic connections.
Spot Magnification: M=2.0, which is a critical parameter for beam quality.
Focus Adjustment Range: ±50mm (optical ratio 1:2 100:200), allowing for flexible adjustment of the focal point.
NA (Numerical Aperture): Max. 0.13 at Fc100.
Centering Adjustment Range: ±1.5mm, enabling fine-tuning of the beam's position.
Focus Acceleration: 7.5m/s², indicating rapid focus adjustment capabilities.
Cutting Gas Interface: Ø10, maximum 25bar (2.5Mpa), requiring high-pressure gas for effective cutting.
Nozzle Cooling Gas Connection: Ø6, maximum 5bar (0.5Mpa), for cooling the nozzle during operation.
Water Cooling Interface: Ø8, maximum 5bar (0.5Mpa), minimum flow 2.0l/min, essential for thermal management.
Operating Temperature: 5~55°C, defining the safe operational environment.
Storage Temperature: -25~+55°C, for safe storage conditions.
Size: 472.3x181 mm.
Weight: Approximately 11 kg.

Usage Features

The BLT641 is designed for ease of installation and operation, with several key usage features:

LED Indicators: Provides clear visual feedback on the device's status.
- POWER: Green for normal power, red for under-voltage alarm, not bright for no power supply/loose connection.
- RUN: Green for normal system operation, red for abnormal motor (high current consumption, mechanical components not running smoothly), not bright for broken cable/loose interface.
- LINK: Green for normal system communication, red for abnormal communication, not bright for broken cable/loose interface.
- SENSOR: Green for normal sensor readings, red for abnormal sensor readings, not bright for broken cable/loose interface.
Gas Interface: Requires cutting gas at a maximum of 25bar (2.5Mpa) and nozzle cooling gas at a maximum of 5bar (0.5Mpa). The quality of cutting gas must meet ISO 8573-1:2010 standards (solid particles - class 2, water - class 4, oil - class 3) to prolong protective lens life.
Water Cooling Interface: Utilizes deionized/distilled water (conductivity < 10 µS/cm) with a recommended pressure of ≤5bar (0.5Mpa) and a flow rate of ≥2.0l/min. Operators must refer to the dew point table to set the cooling water temperature to prevent condensation on optical components.
Electrical Interface: Features PWE and aviation plug interfaces with IP64 protection when dust plugs are in place or cables are properly connected. It is crucial to ensure water circuit connections are tight before removing dust plugs to prevent water ingress.
Bus and Non-Bus System Compatibility: The manual illustrates wiring diagrams for both bus systems (connecting to BCS210E and Hypcut IPC master station) and non-bus systems (connecting to BCS100, BCL4500A, and Cypcut IPC master station). All wiring operations should be performed by trained professionals, and the connected control units (BCS210E or BCL4500A) must be powered off during connection.
Beam Centering: The device allows for XY centering adjustment using a knob to align the focal point with the center of the nozzle. A manual alignment operation involves using scotch tape to assess the laser beam's position and adjusting centering screws.

Maintenance Features

Maintaining the BLT641 cutting head involves specific procedures to ensure longevity and optimal performance:

Clean Environment for Installation: Installation requires a clean workbench (vertical purification, ISO 5/100 cleanliness level, average wind speed ≥ 0.4m/s) to prevent dust and dirt from contaminating optical components.
Cleaning Kit: A dedicated cleaning kit including a strong light flashlight, absolute ethanol (or IPA), dust-free purification cotton swabs, dust-free cloth, and compressed air dust removal tank (or air blower) is necessary for maintenance.
Fiber Interface Cleaning: The fiber interface of the cutting head should be wiped with a clean cloth and anhydrous ethanol. The laser fiber end face must be checked for pollution using a strong flashlight before insertion.
Protective Film/Cap Removal: Special protective caps/films for the optical fiber interface must be removed carefully.
Fiber Insertion and Sealing: After inserting the optical fiber, it must be wrapped and sealed with tape (at least three times) to achieve effective sealing and prevent contamination.
Protective Lens Replacement: The manual provides detailed steps for replacing both the upper and lower protective lenses. This involves opening protective doors, pulling out drawers, removing pressure rings, replacing the lens, and reassembling. It emphasizes preventing dust entry during the process.
Original Accessories: BOCI stresses the importance of using original accessories for replacement and maintenance to avoid potential safety hazards and ensure product quality.
Professional Personnel: All maintenance and installation operations should only be carried out by personnel who have received appropriate training and possess professional knowledge.
Dust Prevention: During maintenance, extreme care must be taken to keep the cutting head and its accessories clean to prevent dust or dirt from damaging the product.

The BLT641 cutting head is a high-performance, intelligent device designed for demanding laser cutting applications, with a strong emphasis on precision, operational safety, and ease of maintenance through structured procedures and clear status indicators.