Handheld Laser Welding Machine

Handheld Laser Welding Machine

1.1 Machine Working Principle

Laser is a new light source, which has the characteristics of coherence, monochromaticity, directivity and high output power, which is incomparable with other light sources. When the laser is focused to one point, the power density on the focal plane can reach 10⁵-10¹³w/cm². Laser welding works by using the excellent directivity and high power density of laser beam.

The laser is generated by the laser, transmitted by the flexible optical fiber cable, focused by the focusing mirror in the welding head, and acts on the weld seam between the processed materials. With the help of protective gas (to prevent the materials from being oxidized), the materials are liquefied to form a specific molten pool, thus achieving the purpose of welding.

1.2 Machine Introduction

1.2.1 Machine Appearance and Structure

The whole hand-held fiber laser welding machine is mainly composed of continuous fiber laser, transmission fiber, hand-held laser welding head, wire feeding system, water chiller, control system and cabinet. It has a lot of new ideas based on humanization and the effectiveness of work in terms of equipment shape, structure and man-machine interface suitable for operation.

The machine features a unified design with a sleek, compact structure, delivering excellent beam quality, consistent energy output, dependable performance, reliable operation, rapid welding speeds, a broad welding range, and extended durability for consumables and parts. During batch production, the equipment accounts for various parameters, allowing precise adjustments and real-time closed-loop data monitoring.

1.2.2 Machine Advantages

Handheld Welding Flexibility: Offers versatile and user-friendly welding, capable of handling any shape or angle.

Compact and Portable: Lightweight and easy to move, ideal for welding large workpieces over long distances or outdoor tasks.

User-Friendly Operation: Simple to operate, requiring no specialized welding skills.

High-Speed Welding: Achieves welding speeds over five times faster than traditional arc welding.

Polished Weld Results: Produces smooth welds with minimal distortion, reducing costs for follow-up grinding or shaping.

1.2.3 Performance Characteristics

Versatile Material Compatibility: Suitable for welding various metals, including carbon steel, stainless steel, high-strength steel, aluminum, copper, and alloys.

Flexible Welding Modes: Supports continuous or pulsed laser output, enabling both thermal conduction welding and deep penetration welding, as well as spot welding, butt welding, overlap welding, sealing welding, and seam welding.

Continuous Fiber Laser: Delivers superior beam quality, maintenance-free operation, photoelectric conversion efficiency exceeding 25%, and a pump source lifespan surpassing 100,000 hours.

Rapid Processing: Ensures swift operation for efficient production.

Minimal Thermal Impact: Features low thermal deformation and a small heat-affected zone, ideal for processing high-melting-point or high-hardness materials.

Precision for Complex Parts: Capable of handling intricate or tiny components, even in vacuum conditions.

Automation Compatibility: Integrates with robotic arms or other automated systems to streamline processing.

Wire-Fill Welding Capability: Supports wire filling, enabling improvements to existing product structures and materials through advanced processing techniques.

1.3 Welding Sample Cases

Main Technical Parameters and Configuration of Equipment

2.1 Main Technical Parameters:

2.3 Main Configuration

Description of Main Units

3.1 Continuous Fiber Laser Generator

Compared with traditional lasers, fiber lasers have higher photoelectric conversion efficiency, lower power consumption and better beam quality. The fiber laser has compact structure and can be used at any time. Because of its flexible laser output mode, it can be easily integrated with system equipment.

Main Features

• High beam quality
• Fiber laser output
• High reliability and long service life, the service life of the pump source is more than 100,000 hours.
• Maintenance-free operation
• High photoelectric conversion efficiency
• The control structure is convenient to use.
• High modulation frequency

Laser Performance Parameters

3.2 Transmission optical fiber

A single laser welding system is equipped with a flexible optical fiber with a length of 10m; The bending radius can reach 80MM. When optical fiber transmits energy, laser fiber has perfect self-protection function. It can automatically cut off the optical path or turn off the laser when the optical fiber is worn and aged, the bending radius is too small, overheating and laser leakage, etc., so as to ensure the safety of personnel and the safety of optical fiber use.

3.3 Hand-held laser welding head and Wire feeding system

3.3.1 Handheld laser welding head

Our Company has introduced a number of portable hand-held optical fiber processing heads suitable for medium and small power laser applications, with diversified interface settings, which can be matched with various optical fiber lasers. The optimized optical design can make the processing more efficient. It is a product with high cost performance.

Characteristics of laser welding head:

• Smart internal design and good interactive control system have expanded the tolerance range and weld width of machined parts, solved the disadvantage of small light spot, and made the weld formation better.
• The shape is light, the body engineering design method is adopted, and the grip is comfortable; Easy to control with one hand, simple to operate and easy to use.
• It has multiple safety alarms, automatically locks the light after removing the workpiece, and has high safety.
• Beautiful weld, high speed, no weld mark, no discoloration, no need for later polishing and less consumables.
• It can be equipped with nozzles with various angles to meet the welding requirements of different products.

Technical parameters:

Type of interface: QBH
Laser emission mode: Coaxial configuration
Laser output power: 2000W
Laser wavelength range: 1080±20 nm
Collimating focal distance: 50mm
Focusing focal lengths: 80mm / 120mm
Shielding gas: Coaxial delivery
Unit weight: 0.9kg
Adjustable width range: 0–6mm

3.3.2 Wire feeding system

The whole wire feeding system consists of wire guiding system, wire feeding hose and wire feeding mechanism on the welding torch head. This wire feeder can be used with hand-held welding head, and is widely used in complex and irregular welding processes in sheet metal processing, kitchen hardware and other industries. This wire feeder can feed aluminum wire, carbon steel wire, stainless steel welding wire, etc.

Standard wire feeding specifications: 0.8, 1.0, 1.2 and 1.6mm

Product Benefits:

• Simple Setup and Longevity: Effortless to install, built to last, operates quietly, and consumes minimal energy.
• Compact and Powerful: Small and lightweight design with strong torque, ideal for long-distance handheld welding wire feeding.
• Smooth and Flexible Feeding: Wire delivery aligns seamlessly with welding controls, providing steady and customizable performance for various applications.
• Intuitive Software Interface: Wire feeding speed is managed through a user-friendly control screen, allowing multiple data sets to be stored and retrieved easily.

3.4 Chiller

Product Advantages:

• Three-layer condenser is divided into technologies, with large refrigerating capacity and good heat dissipation, so as to ensure the durability of the equipment in harsh environment.
• Good water quality, high precision, careful care of the laser to prolong its service life.
• With automatic heating technology, it can reduce the waiting time for customers to start the laser in winter and improve the production efficiency.
• Arc-shaped design, beautiful atmosphere, and upgrade the supporting grade of laser equipment.
• Save energy and electricity, and effectively reduce the production cost of customers.
• Match high, medium and low to meet the diversified needs of customers.

Performance Features:

• Tailored for Fiber Lasers: Designed specifically for fiber laser systems, featuring a sleek and stylish look, with low-temperature and normal-temperature water systems to maintain consistent fiber laser cavity and output conditions.
• Premium Components: Core refrigeration and electrical parts come from globally recognized brands, ensuring outstanding quality and dependable performance.
• Precise Temperature Regulation: Maintains water temperatures at normal and low settings within 1℃ for high accuracy.
• Clean Water System: Includes a high-purity circulating water system with a monitoring setup for real-time tracking and display.
• Enhanced Safety Features: Equipped with alerts for excessive temperature, flow rate, and water level issues, ensuring safe and reliable operation of the laser and water chiller.

3.5 Other Auxiliary Functions (note required)

3.5 .1 Manual automatic conversion function

Hand-held laser welding machine, standard product upgrade, seamless connection with automatic mechanism, quick manual/automatic conversion.

The switch is switched by one key. After automatic is selected, the start switch is connected to the automation equipment through quick plug, and the switch light is controlled by the automation equipment.

3.5 .2 Handheld laser cutting function

The original hand-held laser welder is optimized, and the laser cutting function of the equipment is added to meet the customers’ needs of cutting and welding plates anytime and anywhere. The function conversion can be realized only by quickly changing the laser cutting nozzle, which can cut the sheet below 10mm, and can cut straight lines and circles through auxiliary tooling.

Cutting nozzle cutting	Straight line auxiliary tool	Cutting circle auxiliary tool

Equipment Environmental Requirements

5.1 Equipment operating environment must meet the following conditions

Operating environment of laser:

Auxiliary gas

Protective gas: prepared by the buyer, argon or nitrogen, with purity over 99.99%. First, check whether the nameplate on the special gas cylinder for welding meets the requirements of the gas used, such as purity and pressure. Secondly, introduce the gas from the gas cylinder into the gas inlet in a correct way. Gas flow requirement: ≥ 15 L/min

Power Supply Requirements

1. Power supply specification: 380VAC ±10%,50Hz+220V 50Hz only needs 220V(1000W/1500W);
2. The equipment must be grounded as required.
3. Power quality: line voltage fluctuation < 10%.