QILIN BWT20 Handheld Laser Welding Head and V11 Control Box Instruction Manual

1. Introduction

The QILIN BWT20 is a double axis swing handheld laser welding head designed for precision metal welding applications. This advanced system, paired with the V11 control box, enables various welding techniques including butt welding, stack welding, and sealing welding. It is engineered to produce high-quality welds with a high depth-width ratio, minimal heat-affected zone, and reduced deformation. The BWT20 offers precise control, small focal spot, and high positioning accuracy, facilitating efficient and automated welding processes.

This manual provides essential information for the safe and effective setup, operation, and maintenance of your QILIN BWT20 laser welding system. Please read it thoroughly before use.

2. Product Overview

2.1 Main Components

• QILIN BWT20 Handheld Laser Welding Head: The primary tool for laser welding, featuring a double pendulum design for enhanced control.
• V11 Control Box: Manages the laser welding parameters and system functions.
• Water Cooling System: Essential for maintaining optimal operating temperature of the laser head and source (integrated or external, depending on full system configuration).
• Laser Source: (Typically Raycus, 2000W) Provides the laser beam.
• Accessories: Welding nozzles, graduated tubes, laser protection lenses, various cables and connectors.

2.2 Welding Head Diagram

• Main body of gun head: The central housing for optical and mechanical components.
• Focusing lens: Adjusts the laser beam focus.
• First protective mirror drawer: Holds the primary protective mirror.
• Second protective mirror drawer: Holds the secondary protective mirror.
• Copper nozzle fixed shaft: Secures the welding nozzle.
• Brass mouthpiece: Directs shielding gas and laser beam to the workpiece.
• Locking nut: Secures the mouthpiece/nozzle assembly.
• Button Switch: Activates/deactivates the laser.
• Handle: Ergonomic grip for handheld operation.
• Collimator: Shapes the laser beam.
• Display screen cover: Protects the integrated display.

3. Specifications

The following table outlines the technical specifications for the QILIN BWT20 laser welding head and V11 control box system:

4. Setup

Proper setup is crucial for the safe and efficient operation of your laser welding system. Ensure all components are present and undamaged before proceeding.

4.1 Unpacking and Inspection

1. Carefully unpack all components of the QILIN BWT20 welding head and V11 control box.
2. Verify that all items listed in the packing list are present. Refer to Figure 4 for typical package contents.
3. Inspect all components for any signs of damage during transit. Report any damage immediately to your supplier.

4.2 System Connections

The BWT20 welding head and V11 control box are part of a larger laser welding system. The following steps outline general connection procedures. Always refer to the specific instructions provided with your laser source and chiller for detailed wiring and plumbing diagrams.

1. Connect Welding Head to Control Box: Connect the main cable from the BWT20 welding head to the designated port on the V11 control box. Ensure the connection is secure.
2. Connect Control Box to Laser Source: Connect the V11 control box to your laser source (e.g., Raycus 2000W) using the appropriate interface cables. This typically includes power, signal, and communication lines. Refer to the laser source manual for specific port identification.
3. Connect Water Cooling System:
• Connect the water inlet and outlet hoses from the welding head to your external water chiller.
• Ensure the chiller is filled with the appropriate coolant and is operating within the recommended temperature and flow rate specifications for a 2000W laser system.
• Verify there are no leaks in the cooling lines.
4. Connect Power: Connect the main power cable for the entire system (laser source, chiller, and control box) to a suitable power supply. Ensure proper grounding.
5. Connect Shielding Gas: Attach the shielding gas supply line to the designated inlet on the welding head. Ensure the gas pressure is set according to welding requirements.

5. Operating Instructions

Before operating the laser welding system, ensure all safety precautions are understood and implemented.

5.1 Pre-Operation Checklist

• All connections are secure (electrical, water, gas, optical fiber).
• Water chiller is operational and coolant levels are adequate.
• Shielding gas supply is connected and pressure is set.
• Appropriate laser safety eyewear is worn by all personnel in the vicinity.
• Workpiece is properly secured and clean.
• Work area is clear of flammable materials.

5.2 Powering On and System Initialization

1. Turn on the main power supply to the laser source and chiller. Allow the chiller to stabilize.
2. Power on the V11 control box. The integrated display screen on the welding head (under the cover) should illuminate.
3. Follow the on-screen prompts or refer to the V11 control box manual for system initialization and parameter loading.

5.3 Setting Welding Parameters

The V11 control box allows for precise adjustment of welding parameters. Key parameters include:

• Laser Power: Adjust the output power (up to 2000W) based on material and thickness.
• Pulse Width: Control the duration of each laser pulse (0.1-10ms).
• Single Pulse Energy: Set the energy delivered per pulse (80-120J).
• Spot Shape and Size: The system supports various spot shapes (points, line, circle, ellipse, triangle, 8 words) and adjustable surface (0-5mm). Adjust these via the control box interface to suit the weld joint.
• Welding Speed: Control the travel speed of the welding head.
• Shielding Gas Flow: Ensure adequate shielding gas flow to prevent oxidation.

5.4 Welding Operation

1. Position the welding head over the workpiece, ensuring the correct focal distance.
2. Press the button switch on the handle of the welding head to activate the laser.
3. Maintain a steady hand and consistent travel speed for optimal weld quality.
4. Monitor the weld pool and adjust parameters as needed via the control box.
5. Release the button switch to stop the laser.

5.5 Powering Off

1. Ensure the laser is deactivated.
2. Turn off the V11 control box.
3. Turn off the laser source.
4. Turn off the water chiller.
5. Close the shielding gas supply.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your QILIN BWT20 system.

6.1 Daily Maintenance

• Clean Welding Nozzle: Remove any spatter or debris from the welding nozzle.
• Inspect Protective Lenses: Check the laser protection lenses for any signs of damage, dust, or contamination. Clean or replace as necessary.
• Check Water Cooling: Verify that the water chiller is operating correctly and that there are no leaks in the cooling lines.

6.2 Weekly/Monthly Maintenance

• Clean Optical Components: Carefully clean all accessible optical components (e.g., focusing lenses, protective mirrors) using appropriate optical cleaning supplies.
• Inspect Cables and Connections: Check all electrical, water, and gas connections for wear, damage, or looseness.
• Check Coolant Quality: Periodically check the quality of the chiller coolant. Replace or filter as recommended by the chiller manufacturer.

6.3 Warranty Seals

Note the