Production Manager Must Read: Laser Power Switching Scheme for Multiple Products

It provides a practical solution for the laser power switching required in mixed-line production.It covered core technical points for adjusting laser power, strategies for optimizing mixed production, and ways to solve common problems in switching between products. It helped production managers improve efficiency, reduce downtime, and ensure product quality.

Why is laser power switching so important to mixed-line production?

If the power parameters of laser equipment are fixed, it is easy to produce uneven results when processing multiple product models on the same production line.For example, cutting thin metal plates and thick metal boards requires very different amounts of energy. If the power is not adjusted correctly, the laser will either not penetrate the material, or it will burn it.The most difficult part was that the manual adjustment of power when changing lines was both time consuming and prone to error.In this situation, an intelligent power-switching scheme could save a production manager a few gray hairs.

The three main strategies of laser power switching.

Dynamic parameter storage technology.

Don't have to re-enter parameters every time the line is changed! Store the power, speed, and focal length data of different products in the equipment system in advance, and call them up with a single click when switching models.In practice, it is suggested that bar codes or RFID be used to link products with parameters, so that workers can automatically switch by simply scanning a code. This also eliminates the risk of accidentally entering the wrong number.

Real-time energy monitoring and feedback.

After long use, the laser head is bound to suffer wear and tear, and the pre-set power may not be enough.The system also includes a power sensor that monitors output and automatically adjusts the system if there is any deviation.One automobile parts manufacturer used this strategy, and the rate of good products went up 15 %, and the cost of reworking parts was cut in half.

Modular design.

The parameters of different products are packed into independent modules, such as the "A-type thin plate process package" or the "B-type irregular part process package.When switching, the corresponding module is automatically loaded, and even the type of auxiliary gas and the pressure can be adjusted simultaneously.One electronics company reduced the time it takes to change production lines from 20 minutes to three minutes.

Avoiding these pitfalls can double the effectiveness of the switch.

Don't neglect the warm-up time.

If the laser is not allowed to warm up, it will not work properly, and the result will be defective products.The company has suggested that 5-10 minutes be allowed for warm-up time in production schedules, or that products with similar power requirements be processed consecutively.

Training for operators must be grounded in reality.

But even the best system can be ruined by pressing the wrong buttons.Instead of just lecturing on theory, the company makes short films of actual factory operations and marks the "must see" points.One factory put up stickers of the most common mistakes next to the machines, and the error rate immediately dropped by 40 %.

Regular calibration cannot be neglected.

A power sensor may be lying to you after six months of use; don't wait until a customer complains before calibrating it.I suggest setting up an alarm clock in the system, and doing a complete calibration of all parameters every quarter. The calibration data can be directly synchronized with the MES system, and we won't have to worry about losing the paper records.

Case study: This is the best way to switch.

In a certain electronics parts factory, the laser parameters had to be adjusted eight times a day, with an average waste of 12 minutes each time.After installing the smart switching system and combining it with a time of use pricing strategy, the company is able to concentrate its high-power processing in low-demand periods, saving NT $ 280,000 a year.Even better, they added a feature to the system that alerts them three days in advance when a lens or other part is about to wear out.