Relfar FWH30-DS10E-V4-T Intelligent Double Pendulum Handheld Laser Welding Head

1. Introduction

This manual provides detailed instructions for the safe and efficient operation, installation, and maintenance of the Relfar FWH30-DS10E-V4-T Intelligent Double Pendulum Handheld Laser Welding Head. This versatile 5-in-1 system supports welding, cutting, cleaning, and lithium battery welding applications. Please read this manual thoroughly before using the equipment.

The system features a 7-inch configuration TFT touch screen with a user-friendly interface for setting parameters, monitoring I/O status, alarm information, and motion state in real-time.

2. Safety Precautions

To ensure personal safety and prevent damage to the equipment, observe the following precautions:

• Always wear special fiber laser protective glasses during operation.
• Keep the product clean and prevent the cooling liquid, condensate water, or other foreign matter from intruding into the cavity, as functional contamination can occur.
• Ensure proper ventilation in the work area.
• Do not disassemble the equipment unless explicitly instructed in this manual. Disassembly should only be performed in a dust-free environment.
• Always disconnect power before performing maintenance or cleaning.
• Familiarize yourself with all emergency stop procedures.

3. Product Structure

The handheld laser welding head consists of several key modules:

• X-axis galvanometer module
• Reflector module
• Y-axis galvanometer module
• Focus lens module
• Protective glass module
• Brass nozzle
• QBH module
• Cooling water (inlet/outlet) and air port connections

4. Setup and Installation

4.1 Pipe Connection

The 6mm air tube is connected for butt welding gas protection, with input pressure ≤1Mpa. The cooling water circuit and auxiliary protective gas connections are critical for proper operation.

Requirements:

• Regularly use compressed air (oil-water filtration required).
• Regularly use argon, nitrogen, and compressed air (oil-water filtration required).

The 6mm air tube is connected. The main function is that the excess heat is taken away by cooling through the internal structural member water route when the heat is produced by the light path in the cavity to ensure the welding performance. The series connection of cooling water pipeline is required, with one-in and one-out water circulation connected.

4.2 Optical Fiber Input Installation

The QBH is a horizontal arrangement. To install, take out the dust-proof seal cover. Align the red dot on the fiber optic head with the QBH red dot, and slowly insert the fiber optic head into the QBH.

The QBH is screwed to the locking state: Rotate it to the limiting position clockwise (hearing the "click"), lift up the rotating mantle, and clockwise rotate the mantle until the head of optical fiber is compressed.

4.3 System Wiring

The following figure is a schematic diagram for wiring the whole system. Refer to the detailed interface definitions below.

4.3.1 Electrical Material List

The system requires various electrical components. Ensure all listed items are present and correctly connected.

S/N	Name	Illustration	Quantity	Remarks
1	Intelligent double-swing hand-held welding head		1PCS
2	24V power box		1PCS
3	15V power box		1PCS
4	Ground wire clamp assembly		1PCS
5	7-inch display screen		1PCS
6	Touchscreen 6-core connection cable -1.5m-black		1PCS
7	Handheld laser welding system V4		1PCS

4.3.2 Interface Definitions

The system utilizes various interfaces for power, control, and communication:

• CN1 Wire Feeder Interface: An 8-pin green terminal supporting both motor wire feeding and IO wire feeding.

• CN2 Laser Interface: An 8PIN green terminal defining the laser interface.

• CN3 Temperature Sensor Interface: A 4-pin green terminal for temperature sensor connection.

• CN4 Reserved Serial Port Interface: A 5-pin green terminal without wiring.

• CN5 Power Supply Interface: All 6PIN green terminal, providing a power interface for mainboard and galvanometer externally, with voltage: DC 24V (DC 24V) and DC±15V (DC±15).

• CN6 External Start and Interlock Interface: A 4PIN green terminal.

• CN7 General Input Interface 1: A 6PIN green terminal of NPN type.

• CN8 General Output Interface: A 6-pin green terminal. Uses OC output, can directly drive relays, with a maximum current of up to 500mA.

• CN9 Common Input Interface 2: A 4-pin green terminal of NPN type.

• Galvanometer Interface: The system provides two DB9 galvanometer interfaces, one DB9 male connector and one DB9 female connector.

5. Operating Instructions

5.1 HMI Function Introduction

The handheld laser welding control system operating panel (HMI) adopts a 7-inch configuration TFT touch screen with a beautiful interface and convenient operation. It allows setting laser-related parameters, monitoring input and output IO status, alarm information, and motion state in real-time.

Key HMI Functions:

• Scanning Parameters: Used to set relevant parameters during galvanometer scanning processing.
• Parameter number: The system supports the storage of 9 groups of parameters.
• Scanning speed: Used to set the scanning speed of the galvanometer.
• Laser power: Set the output light power during welding.
• Scanning length: Used to set the length of the laser scanning in the X direction.
• Scanning width: Used to set the width in the Y direction of the laser scanning.
• Scanning type: Used to set 5 types of scanning waveforms.
• Red Light | On/Off: Controls the red light switch, indicating the red light of the laser.
• Allow/Prohibit | Laser Emission: This button allows or prohibits laser emission.
• Manual Blowing: Clicking on the manual blowing area will continue the blowing process. Clicking it again will turn off the blowing.

5.2 HMI Operation Introduction

The HMI allows for various parameter adjustments and system controls.

• System Parameter Settings: After parameter modifications, they need to be saved to take effect.
• Early Vent Time: When starting the processing, a delayed vent can be set. When the external start button is pressed, air is blown and delayed for a period of time, and then the laser starts to come out.
• Delayed Gas Shut-off Time: When processing stops, a delayed gas shut-off can be set. When processing is stopped, first stop the laser output, delay for a period of time, and then stop the air blowing.
• Opening Power: Used to set the initial power of the laser, which is a percentage of the welding power.
• Progressive Opening Time: Controls the time it takes for the laser's output to slowly rise to the set power.
• Light-off Power: Used to set the light-off power of the laser, which is a percentage of the welding power.
• Progressive Turn-off Time: The time used to control the slow decrease of the laser's turn-off power.
• Language: Used for switching languages.
• The length of the early deceleration: Control the distance of the early deceleration in the gradual time of turning off the light.
• Laser frequency: Used to set the PWM frequency of the laser.
• Duty cycle: Set the duty cycle of the PWM modulation signal, with the setting range being 1% ~ 100%.
• Double-click light output enable: Select the light output mode and whether to double-click the button. If not enabled, click the button.
• Enable security lock: Select whether to perform security lock protection.
• Proportional coefficient: Used to set the maximum range of the X-axis and Y-axis of the galvanometer. This parameter needs to be consistent with the actual range of the galvanometer; otherwise, the actual light output length and width may not be accurate. The default parameter does not need to be set.
• Field lens type: Reserved for switching between different field lenses. Reserved parameters do not need to be set.

5.2.1 Parameter Settings for Welding, Cutting, Cleaning, and Energy Storage Welding

The system supports various modes, each with specific parameter configurations. The video demonstrates these functions:

Video 1: Demonstration of welding, cutting, cleaning, and energy storage welding functions.

• Welding Mode: Set welding mode, continuous and pulse modes.
• Wire Feeding Parameters: Used to set parameters related to wire feeding, wire supplement, and withdrawal.

• Cutting Mode: Parameters for laser power, frequency, and scanning length/width for cutting operations.
• Cleaning Mode: Parameters for laser power, frequency, and scanning length/width for cleaning operations.
• Energy Storage Welding: Parameters for laser power, frequency, and scanning length/width for energy storage welding, typically used for lithium battery welding.

5.3 APP Connection

The RDWelder mobile APP is suitable for remote control, supporting various types of product applications such as single pendulum welding, double pendulum welding, single pendulum cleaning, and double pendulum cleaning. Users can connect the board card through this APP to achieve wireless connection control. It provides equipment and constantly traveling back and forth. It supports remote viewing of equipment status and parameter adjustment, facilitating equipment management and maintenance. The APP also has rich technical center resources. It is provided for customers to install and maintain equipment, review process data, assist in troubleshooting, and refer to application cases.

The handheld APP and control card support two connection modes: AP mode and STA mode.

5.3.1 AP Mode Connection

• In AP mode, the APP is directly connected to the control card. The control card emits a WiFi hotspot signal. Customers can use mobile devices such as mobile phones to connect to the WiFi hotspot signal emitted by the control card. After the connection is completed, the board card can be controlled using the APP. Both the touchscreen and the APP use WiFi ICONS for status display.

Board card Settings:

• Click the upper right corner of the touch screen to enter the WiFi configuration page and configure the WiFi hotspot.
• Set the connection mode to AP and set the name and password of the WiFi hotspot. If the WiFi is turned on, you need to first click the < Turned On > button to turn off the WiFi. When the WiFi icon goes off, you will enter the configurable WiFi setting state.
• After the configuration is completed, click the < Turn on WiFi> button, and the system will turn on WiFi again.

5.3.2 STA Mode Connection

• In STA mode, the APP and the control card are connected to the cloud via the Internet. After setting the control card to STA mode, it is necessary to connect to WiFi to access the network. Access the server through traffic data to obtain the device status and perform operation control. Both the touchscreen and the APP use Internet of Things cloud ICONS for status display.

6. Maintenance

6.1 Structure of Optics Lens

The assembly is completed in a dust-free plant at the time of replacement of parts. In principle, other modules are forbidden to be dismounted except that the protective glass drawer can be disassembled and assembled. If it is necessary to check the collimating lens, focus lens and galvanometer lens, the product shall be put into a clean environment for disassembly.

6.2 Cleaning of Optics Lens

When the optics lens are cleaned, the operation method and attention points are as follows:

• Tools: Dust-free gloves or dust-free fingerstall, dust-free wiping cotton swab, isopropyl alcohol, and canned dry and pure compressed air.
• Spray the isopropyl alcohol onto the dust-free cotton swab, align the lens to eyes, gently pinch the side edge of the lens with left thumb and index finger and hold the dust-free cotton swab with right hand to gently wipe the front and back of the lens in a single direction from bottom to top or from left to right (avoid wiping back and forth to avert the secondary contamination of lens), blow the surface of the lens with filling dry and pure compressed air and confirm the surface of lens is free from foreign matters after cleaning.

6.3 Disassembly and Assembly of Optics Lens

6.3.1 Disassembly and Assembly of Collimation Lens

Tools: 2mm inner-hexagon wrench, dust-free cotton swab, alcohol.

• The disassembly and assembly shall be completed in a clean place. When the lens are dismounted, the dust-free gloves or dust-free fingerstall.
• Disassembly steps:
  1. Loosen the M2.5 hex socket head cap screw in the figure by hand with a 2mm hex wrench.
  2. Take out the focus drawer module by direct drawing/pulling in the horizontal direction.
  3. Seal the port with textured paper to prevent the dust from entering the cavity, resulting in pollution.
  4. Rotate the gland for 90° after pressing it downward gently and take out the gland by two bosses aligning to left/right opening to replace the collimation lens.

6.3.2 Disassembly and Assembly of Focus Lens

Follow similar steps as for the collimation lens, ensuring a clean environment and careful handling.

6.3.3 Disassembly and Assembly of Protective Glass

• The disassembly and assembly shall be completed in a clean place. When the lens are dismounted, the dust-free gloves or dust-free fingerstall.
• Replace the protective glass 01:
  1. Hold both sides of the handle of the green drawer module 1 with hands to draw out the protective glass in the horizontal direction. Pay attention to dust prevention and seal the exposed window on the cavity with textured paper to prevent the dust from entering the cavity, resulting in pollution, and then replace the protective glass.
  2. Gently press the gland down for 90° rotation, and loosen it when two lugs align to two notches to take out the gland to replace the protective glass.
• Replace the protective glass 02:
  1. Take out the green drawer handle module 1 to take out the handle module 2 in the horizontal direction. Pay attention to dust prevention and seal the exposed window on the cavity with textured paper to prevent the dust from entering the cavity, resulting in pollution, and then replace the protective glass.
  2. Gently press the gland down for 90° rotation, and loosen it when two lugs align to two notches to take out the gland to replace the protective glass.

6.4 Module Replacement

After the replacement of hardware components, the equipment can be powered on anew. Confirm the replacement of the hardware component, and the system processing mode switch will be over.

6.5 Welding Seam Cleaning and Replacement

Remove the welding nozzle and replace the special nozzle for welding seam cleaning.

6.6 Energy Storage Welding Replacement

Remove the 3 *M 2.5 * 6 hexagonal socket head screws of the welding gas ring (using a 2mm hexagonal wrench), replace the specialized energy storage welding nozzle assembly, and use the 3 *M 2.5 * 6 hexagonal socket head screws (using a 2mm hexagonal wrench) for installation.

7. Troubleshooting and Alarm Information

7.1 Monitoring Protection Device

The system includes monitoring for protective lens temperature. To set the temperature alarm limit:

[Home Page]→[System Parameter]→[Equipment Parameter]→[Input Password: 666888]→next page→ lens temperature alarm limit value.

It is suggested to set the set value of lens temperature to 50. After the lens temperature exceeds the set value, the alarm caution will arise on the home page and the display light on the side of the handheld plumb joint will turn to red.

7.2 Alarm Information

The alarm information includes: safety clip alarm and machine alarm. The safety clamp alarm is caused by the safety clamp not being reliably connected to the cleaning head.

The machine alarms include three types: laser alarm, water-cooling machine alarm and low voltage alarm. In the alarm information interface, multiple alarm messages can be displayed, with a maximum of 3 pages. They can be switched between the previous page and the next page.

When the alarm is triggered, the laser output will be stopped at this time, the galvanometer will stop moving, and the corresponding alarm information will be prompted. Users can check the relevant hardware problems and clear the alarm according to the alarm prompt. After the alarm is cleared, the alarm record of the machine's alarm will still exist in the alarm information. At this time, you can manually clear the alarm by entering the alarm information interface. If the alarm is not cleared, it will continue to prompt when the alarm is manually cleared.

[Gun head light emission control logic: Click the switch button to preview the graphic with red light. After clicking, continuously double-click the switch button to emit laser.]

8. Specifications

The following table details the key product parameters:

Overall dimensions of main board: (196.8 * 111.8 * 52) mm

Product dimension figure (Touch Screen): External dimensions: (210*150*23.5) mm

9. User Tips

• For optimal welding results, ensure the workpiece is clean and free of contaminants before starting.
• When switching between different functions (welding, cutting, cleaning), always verify that the correct nozzle and parameters are selected on the HMI.
• Regularly check the cooling water and air pressure to prevent overheating and ensure consistent performance.
• If experiencing issues with wire feeding, check the wire path for any obstructions and ensure the wire withdrawal control interface is properly connected.
• For precise control and monitoring, utilize the mobile APP's AP or STA mode connection features.

10. Warranty and Support

For warranty information, technical support, or service inquiries, please contact your authorized Relfar dealer or the manufacturer directly. Keep your purchase records and product serial number handy for faster service.