Troubleshooting Laser Welding Gun Issues: Weak Light and Sparking at Copper Nozzle

Laser welding machine are widely used in various industries for their precision and efficiency. However, issues such as weak light and sparking at the copper nozzle can hinder the welding process. In this article, we will analyze the possible causes of these problems and provide solutions to prevent them from occurring in the future.

Analysis of the Issues:

The weak light and inability to fuse may be caused by damaged lens components, including protective lenses, focusing lenses, collimating lenses, and reflectors. Any damage to these components can result in the observed issues. It is recommended to start by replacing the protective lens and checking the focusing lens, reflector, and collimating lens for any damage. Replacing the damaged lens components should resolve the problem. Additionally, the sparking at the copper nozzle may be due to a focus issue, which should be addressed as well. It is also important to inspect the laser fiber optic head for any dirt or damage.

Lens Damage Analysis:

Damage Classification: The abnormal motor swing caused by interference or misalignment of the red light can burn the sealing ring together with the lens.

Convex Surface Damage of the Platform Lens: This type of damage is commonly caused by contamination during lens replacement without proper protection. It appears as black spots.

Flat Surface Damage of the Platform Lens: Diffuse reflection of the laser beam often causes this type of damage, resulting in focal points on the lens and burning of the coating. It appears as white spots. The same principle applies to convex surfaces.

Protective Lens Damage: This is usually caused by residue or contamination during replacement.

Abnormal light emission due to an excessively sharp Gaussian beam from the laser, resulting in a sudden white spot in the middle of any lens.

Troubleshooting:

To resolve the issues, it is recommended to replace the damaged lens components. For specific replacement procedures, please refer to the installation manual.

Preventive Measures:

To better operate the fiber laser welding machine and avoid frequent lens-related replacements during handheld welding, the following preventive measures can be taken:

Use original manufacturer lenses, as lenses purchased online may not guarantee optimal light transmission.

Pay attention to contamination prevention during lens replacement.

Avoid vertical welding techniques, especially when welding high-reflective materials.

Protect the lens from damage by implementing preventive measures.

Replace damaged protective lenses promptly.

Prevent interference and ensure effective grounding.

Conclusion:

By understanding the causes of weak light and sparking at the copper nozzle in laser welding guns, appropriate troubleshooting and preventive measures can be implemented. This will help ensure smooth and efficient welding operations, reducing downtime and improving overall productivity.