The MAZAK LASER, specifically the STX SC model, is a sophisticated machine designed for cutting various materials with high precision. It utilizes a laser beam for processing and is equipped with several integrated systems to ensure optimal performance and safety.
Function Description:
The core function of the MAZAK LASER is to cut materials using a laser beam. It operates in two main programming modes: "Press Mode" and "Cut Mode." The machine supports linear and circular interpolation for complex geometries, and features like cutter radius compensation (G41/G42) allow for precise control over the cutting path, accounting for the laser beam's discernible diameter. It also offers advanced features such as power ramping (G81) for adjusting cut conditions at corners or intricate geometries to prevent burning or rounding, and focal position control (G87) for fine adjustments to the focal point. The machine can be operated in absolute (G90) or incremental (G91) modes for axis movement, and work coordinate systems (G54-G59) can be used to define reference points for cutting. For automated material handling, the machine can be equipped with a load/unload cell, allowing for programmed loading and unloading sequences (M81, M82, M83).
Important Technical Specifications:
- Laser Gas Supply Pressure: Primary gauge should be >142 psi (10 Kg/cm2). Secondary pressure for laser gas should be 35-40 psi.
- Oxygen Secondary Pressure: 140 psi (no greater).
- Laser Gas Regulator (Machine Side): Set at 1.0 Kg/cm2 (green marker).
- Laser System Pressure (STX SC): 1.5 Kw = 54 torr, 2.0 Kw = 50 torr.
- Chiller Unit: Reservoir holds approximately 40 gallons of distilled water, corrosion inhibitor, and fungicide. Air pressure gauge set at 5.0 Kg/cm2. Water pressure set at 3.5 Kg/cm2. Chiller temperature 17.5 degrees Celsius +/- 1 degree.
- Axis Movement Commandable Values:
- Cut Mode: X,Y (999.9999 in. / 9999.999 mm.), Z (99.9999 in. / 999.999 mm.)
- Press Mode: X,Y (999.999 in. / 9999.99 mm.), Z (99.999 in. / 999.99 mm.)
- Power Ramping (G81): Ramping distance determined by Parameter #29 "Adaptive Control Length" (inches) in L PLUS Control.
- Assist Gas Pressure Control (G88): Maximum pressure value P60.
- Pulse Types (G82): Normal pulse (M69), enhanced pulse (M68 - not available on NTX models), high speed pulse (M67 - not available on NTX or STX SC).
- Mechanical Booster Oil Type: OR-7000.
- Vacuum Pump Oil Type: OHE-270 (LEYBOLD).
Usage Features:
- Start-up Procedure: Involves turning on the air compressor, opening laser and assist gas cylinders, turning on the main breaker, and activating laser power and high voltage via the operating panel buttons.
- Power Off Procedure: Reverses the start-up, including pressing "LASER HIGH VOLT" OFF, "LASER POWER" OFF, turning the "LASER" key switch to OFF, pressing "POWER" OFF, and closing gas cylinders.
- Focusing Procedure: A detailed process involving placing a stainless steel plate, removing the stylus foot and nozzle, positioning the torch, inputting manual laser parameters (peak power, frequency, duty, pressure), and adjusting the Z-axis until a blue flame is observed.
- Nozzle Centering: Involves placing tape over the nozzle, lowering the Z-axis to cutting height, quickly opening/closing the shutter, and adjusting the nozzle with knurled knobs until the beam is centered.
- Profiler Adjustment: Ensures the nozzle is centered in the stylus plate and adjusts the Z-axis for proper gap.
- Non-Contact Sensor: An optional feature that allows profiling without physical contact, using capacitance to detect material. It is only effective on metal and not on non-metallic materials.
- Program Restart Function: Allows continuation of operation from the point of an alarm without repeating previously cut sections, provided no tipped parts obstruct the torch.
- Machine Graphics (L PLUS CONTROL): Enables simulation of cutting paths to check for overtravels and visualize the part on the screen, with adjustable graphic speed and scale.
- Cutting Plastic Coated Metals: Offers specific techniques like "Profiler Off Method" for small holes/parts and "Pre-Burning the Pierce Point Method" for larger holes/parts to prevent plastic ballooning.
- Supporting Thin Materials: Suggestions include ensuring support slats are not worn, adding more slats, or cutting a template to support very thin materials.
- Multiple Part Example: Illustrates programming for repeating parts across an entire sheet, typically starting from the lower left corner and cutting in the "y" plus direction.
Maintenance Features:
- Routine Inspection: Daily checks for laser gas and assist gas supply pressure and quantity, chiller water level, pressure, and air pressure, lubrication oil quantity, and chiller condenser/cover cleanliness.
- Focus Lens Cleaning: Recommended weekly for mild/stainless steel, daily for aluminum/non-metallic materials. Involves a careful procedure for removing, cleaning with methanol and lens paper, and reinstalling the lens, emphasizing strict precautions against contamination and damage.
- Vacuum Pump Oil Change: Recommended after the first 750 hours, then every 1500 hours or 1 year, or if oil darkens. Involves running the pump to warm the oil, draining, refilling with OHE-270, and checking for leaks.
- Vacuum Pump Demister Filter: Replaced if contaminated with oil.
- Mechanical Booster Oil Change: Recommended every 2000 hours or 1 year, or if oil darkens. Involves running the booster to warm the oil, opening the "Air Admit plug" for 20 minutes to prevent resonator contamination, draining, refilling with OR-7000, and cycling "Laser Power" to purge air.
- Chiller Unit Maintenance:
- Flushing Procedure: Every 6 months with recommended inhibitors/fungicides, or every 3 months otherwise. Involves draining, filling with tap water and "CITRANOX" flushing agent, running for 8-12 hours, draining, rinsing with tap water, and refilling with distilled water, corrosion inhibitor ("ISOGUARD"), and bactericide/fungicide ("GAX-26").
- Heat Exchanger Cleaning: Regularly (every 2-3 days depending on environment) by vacuuming or blowing out with compressed air.
- Mist Filter Element Replacement: Checked every 1000 hours and replaced as necessary.
- Lubrication:
- Chip Conveyor: Monthly lubrication of hinge links, side chain, and main shaft bearing with light machine oil.
- Axes: Automatic lubrication system for ball screws and LM guides (Mobil Vactra Oil No. 2). Alarm occurs when oil is low.
- Dry Air Filter (Machine): Element acts as a filter and moisture indicator; turns pink if water is in the air line, indicating contaminated filters in the air system.
- Preventative Maintenance Schedule: A detailed table outlining inspection items, intervals (Daily, Weekly, Monthly, Every 200/1000/1500/2000/3000 HRS, Every 2 Months, Every 6 Months), and corresponding tasks.
- Procedure to Clear Maintenance Alarms: For super charged series machines, alarms appear after 2000 hours as reminders. The procedure involves turning off/on laser power, pressing specific menu keys, and adjusting parameter 5111 to reset the alarm counter.
- Procedure to Save Machine Parameters: For L1 & L2 Control, this procedure allows saving hidden "NC" parameters to a device (PC or CAD) for backup and reloading.
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