Multi-Station Laser Production Line Dust Removal Design: A Practical Guide to Ductwork Layout and Equipment Integration

We offer complete solutions to dust removal in multi-station laser production lines, covering such areas as duct layout design, system integration, and troubleshooting common problems.It explains how to optimize dust removal efficiency and reduce equipment wear and tear, and is a useful reference for technicians and production managers in laser processing plants.

Why is it so important to keep the production line clean?

We all know that the smoke and dust produced during laser cutting and welding not only pollutes the environment, but also affects the life of the equipment and the accuracy of the processing.This is especially true for multi-process production lines, where smoke and dust easily spread from one machine to another, and workers have to clean the machines and replace the filters every day if the dust removal system isn't well designed.Thus, a reliable dust collection system will be an "invisible helper" in boosting production efficiency.

Air ducts: Don't let the dust "block" the road.

First we calculate the air flow, then we draw the blueprints.

Many first-time users are eager to draw the pipes, but end up with insufficient suction later on.I suggest calculating the required airflow first according to the laser power and material type for each work station.For example, the smoke particles from cutting stainless steel are finer. So the demand for air volume is about 20 % higher than for carbon steel.These data are used to determine the relative proportions of the main and branch pipes, so that the drawings will not just be for show.

The number of elbows should be reduced and more 45-degree three-way joints should be used.

The more bends there are in the pipes, the greater the wind resistance.I once saw a factory that had installed a dust extraction system with a dozen right-angle elbows. The result was that the suction force at the workstations furthest from the fan was almost zero.Later, the 90-degree elbows were replaced with 45-degree elbows, and the airspeed increased by 30 %.Remember: If you can use a 45-degree elbow, don't use a 90-degree elbow!

Smart systems: Linking the equipment

Where is the best place to install sensors?

Don't put the dust sensors at the top of the equipment--the machines will be started up before the dust has even risen that far.Experiments have shown that placing the sensor 15 to 20 centimeters below the laser head will trigger the fan to respond most quickly.If it is a multiple-station production line, it is suggested that each station be equipped with its own sensor to avoid all machines running at full power at the same time.

The "perfect match" of wind turbines and laser equipment.

The worst situation I've had to deal with is when the laser stops working, but the fans keep spinning.Later, a 30-second delay module was installed, which ensures that the smoke is thoroughly cleared after the machine is turned off.On the other hand, if the fans are not ready when the laser equipment is turned on, it is important to remember to add an interlock function to the control system. This small modification can prevent many unexpected shutdowns.

Regular maintenance: Don't wait until you get clogged up to start worrying.

How to know when to replace your filter.

First, check the pressure gauge, and if the pressure exceeds 1500Pa, it's time to change the filter. Second, check the air outlet. If you can see dust coming out, it's time to change the filter. Third, check the production volume. For example, when cutting carbon steel, you should change the filter every 80 hours.Don't try to save money on the filter material by damaging the blower. The cost of replacing the blower is enough to buy filter material for three years.

Lazy man's way of cleaning the pipes.

At the low point of the pipeline, a dust outlet is added, and the dust is blown out once a month using compressed air.I've seen manufacturers who have lined the insides of their pipes with teflon, so that smoke and dust don't stick to the walls. This can extend the cleaning cycle threefold.Although the initial investment is high, the time saved on maintenance is definitely worth it.