Real-life example: Upgrading to 50W laser head boosts production by 270 %

A manufacturing company that upgraded its 30-watt laser head to a 50-watt high-power device was able to boost its daily output from 120 pieces to 450, a 270 % increase.The article analyzes the key steps, precautions, and test data involved in upgrading the laser head, providing a reference for equipment upgrades for manufacturing enterprises.

Why did you choose a 50-watt laser head?

Originally, our factory used 30W lasers to cut metal parts, and we could only complete 120 pieces a day.This year orders have suddenly gone up threefold, and the old equipment simply can't stand the pressure. It overheats and shuts down all the time, and changing the coolant and adjusting parameters takes up a third of the workers 'time.

It wasn't until last month, when I saw a demonstration of a 50-watt laser head cutting 5mm stainless steel at twice the speed of our machine and without producing any burrs, that I finally realized we were behind the times.It was only then that he began to think about upgrading his equipment.

The whole process of upgrading the laser head is recorded.

Preparation for the renovation.

I asked the equipment manufacturer to do a site inspection to confirm that the structure of our machine could accommodate the new laser head.He carefully examined the wear on the guide rails--after all, the new laser head has more power, and if the guide rails are not precise enough they could damage the machine.Finally, after three days of maintenance, two rusted gears were replaced.

Key points in the calibration of parameters.

The new laser head cannot be plugged in and used immediately.The technician, as he showed us how to adjust the focus, stressed repeatedly that the amount of defocus should be adjusted depending on the material being cut.For example, aluminum alloy must be cut 0.3 mm thinner than stainless steel. Such details directly affect whether the edges of the finished product are flat.

Comparing data.

Before:

- Single item cutting time: 4 minutes 15 seconds.

- Average number of breakdowns per day: 3-5.

Monthly cost of supplies: NT $ 2800.

After upgrade:

- Time to cut a single piece: 1 minute 50 seconds.

– Continuous 8-hour operation without downtime.

40 % reduction in consumables costs.

The most surprising result of the upgrade was that the accuracy of the machining improved from ± 0.2 mm to ± 0.05 mm, and customers never complained about dimensional deviations again.

Practical Suggestions for Fellow Journalists

1. Before upgrading, back up the original settings of the device.

2. A new laser head requires a 2-week break-in period. It is recommended that the power be reduced by 10 % for the first 3 days.

3. Workers must be retrained in safety procedures--the metal vapor produced by high-power lasers damages protective eyewear more easily.

Now the old workhorse in the factory can produce a steady 450 pieces a day, and the night shift workers no longer have to wait for the machine to cool down.His only regret is that he didn't decide to upgrade six months earlier.