HIGHEST DYNAMICS, EASY INTEGRATION
The AXIALSCAN FIBER RD-30 is a highly integrated pre-focusing beam deflection unit for use in industrial production environments. Whether laser welding, cutting or cleaning, thanks to its dust-proof housing and integrated collimation optics, the AXIALSCAN FIBER RD-30 is the ideal deflection unit even under harsh production conditions. The focus here is all on dynamics and productivity.
Thanks to our highly dynamic z-axis with RAYVOLUTION DRIVE technology, the AXIALSCAN FIBER RD-30 can use the full dynamics of its XY scanners without losing the z-position of the focus. This makes the AXIALSCAN FIBER-30 RD ideal for processing very thin materials such as battery foils or bipolar plates for fuel cells. Here, a stable penetration depth and a uniform focus are particularly important in order to avoid damage to the bipolar plate and to obtain a uniform cutting result.
Thanks to its high power compatibility of up to 6kW, the AXIALSCAN FIBER RD-30 is well suited for welding battery housings or cell connectors of prismatic cells. Due to the large processing fields, the AXIALSCAN FIBER RD-30 also enables hairpin welding of electric motors without the need to move the motor or the deflection unit.
Smallest spot diameter
Stable focus position
Easy integration & maintenance
Production in the clean room
Thanks to its optimized dust-proof design, lightweight mirrors and the innovative RAYVOLUTION DRIVE technology, the AXIALSCAN FIBER RD-30 offers the ideal combination for maximum dynamics in industrial production environments. This focus on production is reflected in various aspects: For example, the digital electronics of the scanners enable convenient read-back of position data, which can then be easily merged with measurement data from the coaxial process light and camera port. This enables precise process monitoring and control. And also the housing is designed for productivity: Thanks to “quadruple design” with 100% overlap across the build area, 4 lasers can work simultaneously on one component, enabling even theshortest cycle times in demanding production lines.
And it is precisely this combination that makes the AXIALSCAN FIBER RD-30 the optimal solution for your production. See for yourself:
The welding of busbars is one of the most challenging welding applications in the field of e-mobility and battery production. A reason is that the battery cells can vary in height by up to 1 mm and an extra mechanical tolerance is often caused by the transport system of the battery packs. Nevertheless, the cells must be welded within a small process window due to the thin battery housing. This requires precise process control and represents a major challenge for the system integrator.
Battery module made of cells connected with laser-welded busbars (source: Laserax)
Here, the AXIALSCAN FIBER RD-30 offers a good solution. With its large processing field of up to 1000 x 1000 mm2, it enables the processing of complete battery packs without having to move the battery or the laser system. This significantly reduces the complexity of the overall system. Thanks to its highly dynamic z-axis with RAYVOLUTION DRIVE, the AXIALSCAN FIBER RD-30 can quickly and precisely compensate for height differences between batteries and ensures that the z-position of the focus remains constant in the process window, even at high scan dynamics. At the same time, the achromatic process light output and the tracked camera port via the RAYSPECTOR enable precise process monitoring and control.
As a specific solution for welding busbars, the AXIALSCAN FIBER RD-30 can additionally be combined with the RAYLASE DISTANCE MEASURMENT SENSOR and the RAYGUIDE MATCH software to form the BUSBAR WELDING MODULE. In this expansion stage, the AXIALSCAN FIBER RD-30 offers a fully automated solution for this important process step in battery production and thus helps to meet the increasing demand for batteries through an optimized and highly efficient process.
In comparison to a standard z-axis, the RAYVOLUTION DRIVE follows the xy-mirrors without any time delay and thus ensures synchronous movement in 3D.
Pre-focusing beam deflection units such as the AM MODULE III use a combination of moving and fixed lenses in front of the scan mirrors to focus the laser. To keep the focus in a constant z-plane, the lens is tracked and the focal length adjusted with each movement. But at higher dynamics, many focus shifters can no longer follow the movement of the XY mirrors, which can lead to non-uniform power input in the powder.
To take advantage of a pre-focusing system and at the same time use the full dynamics of the XY deflection unit, the RAYVOLUTION DRIVE (RD) technology was developed. It is based on the moving coil principle to shift the lenses, which allows very fast movements of the lens. It can thus follow even highly dynamic XY mirrors without delay and maintain a stable z-position of the focus.
In addition, an innovative mount used for the RAYVOLUTION DRIVE allows highly accurate alignment and guiding of the lenses even under dynamic movements and enables excellent imaging performance of the lens system. Even single mode fiber lasers or special beam shaping like Ring mode lasers remain nearly undisturbed. The frictionless guidance also leads to significantly reduced wear and makes the RAYvolultion Drive technology very low-maintenance overall.
With its high dynamics and reliability under production conditions, the RAYVOLUTION DRIVE technology is made for industrial additive production. It ensures optimal flat-field correction even at high scanning speeds throughout the entire up to 650 x 650 mm2 processing field. In addition, the RAYVOLUTION DRIVE enables highly dynamic scanning strategies such as hatching with a constant focus position, making the AM MODULE III the ideal solution for precise and highly dynamic AM applications.
In precise manufacturing processes, the adjustment of the workpiece is a critical step. While complex manual adjustment is still tolerable in the laboratory, alignment becomes very time-consuming even for small series. To simplify this part of the process preparation, we have developed RAYGUIDE CLICK&TEACH. After all, it is often much easier to detect the position of the workpiece and adjust the movement of the deflection unit accordingly.
Automatic edge detection with RAYGUIDE MATCH for correction of the workpiece position
Images of the processing field are captured by a camera on the AXIALSCAN FIBER RD-30 and displayed as background in the RAYGUIDE software. The RAYSPECTOR ensures a sharp image in the entire image field through its dynamic focus tracking. The RAYGUIDE CLICK&TEACH plugin can then be used to adjust the laser processing to the real positions and dimensions.
But what if you want to take the step to real series production? Any manual step here can make the whole process unprofitable. In this case RAYGUIDE MATCH offers help. The plugin extends the camera-based position recognition by an automatic feature recognition. Position marks on the workpiece are detected and the laser processing is corrected autonomously. As a result, part feeding and alignment can be performed with higher tolerances, and precise laser processes can be realized fully automatically without manual interaction by a user.
Data is the new gold. Because it allows process control, process optimization and quality control. Therefore, it is important to collect data already during the manufacturing process. But process monitoring only works smoothly if the scanning system and the components are optimally matched. For example, on-axis data can only be meaningfully interpreted if it is combined with the position values of the mirrors. The AXIALSCAN FIBER RD-30 offers optimal conditions for such a task, because the position values of the galvos can be read back together with the data of a pyrometer via the SP-ICE-3 card, and then conveniently combined to a heat map.
Highspeed camera images of a melting pool with donut and Gaussian beam caustics
For observation of the welding process with high-speed cameras, the combination of RAYSPECTOR and AXIALSCAN FIBER RD-30 also offers the right solution. Thanks to the RAYVOLUTION DRIVE, the camera's imaging optics can be tracked dynamically and synchronously with the scan mirrors. This allows the laser process to be observed always in focus. Such information is of interest during process optimization, as it helps the user to recognize the dynamics of the melt pool and possible irregularities and to optimize the process parameters.
INTUITIVE PROCESS SOFTWARE
Our software solution for a quick and easy programming of your scanning solution. User-friendly set-up and calibration of the deflection unit and effortless automation through the built-in API.
Technical specifications are important and often decisive. But at RAYLASE, we believe that there is more to it than pure technology that matters. For this reason, we are your partner for reliable and successful laser processes and offer more than just technical components.
Modern production systems for laser processing are usually designed specifically for one process step and are highly optimized. It is therefore important to consider the interplay with the other machine components when selecting suitable beam deflection units. At RAYLASE, we therefore always have the entire solution in mind and offer our customers assistance in putting together suitable components.
For many processes, the beam deflection unit is a decisive component. Often it determines whether the desired spot parameters and processing speeds can be implemented on the component. To identify the optimal solution here, we support our customers in selecting the right beam delivery components and sensor technology. and perform simulations of the laser processes developed by our customers. In addition, we provide support in the parameterization of the laser and deflection unit or software functionality through the experts at our Technical Competence Center TCC.
Our customers are the experts for their application - we are the experts for our beam deflection units.That's why we support our customers during the commissioning of our products - if necessary also directly on site. In this way, we at RAYLASE ensure that our system is optimally adjusted and permanently delivers what it is capable of.
Modern laser deflection units are complex systems. Therefore, it is important to have a good knowledge of their characteristics. Because only when users know how the various parameters interact the optimum process becomes possible. For this reason, we at RAYLASE put a high priority on training for our products. In addition, we also offer our customers on-site training directly on the system, if required, to enable users to operate the system independently.
Together you achieve more. At RAYLASE, we are convinced about this. That's why we place great value on cooperation in a spirit of partnership and open communication at equal level – from expert to expert. Because only when we jointly find the best solution and successful integrate it into the machine, everyone involved benefits in the end - our customers, us and also the end users.