As we all know, laser cutting machines have a few vulnerable components, including ceramic rings, cutting nozzles, focusing lenses, reflector mirrors, and protective lenses. This article primarily focuses on ceramic rings, explaining their crucial role and the importance of maintaining them to ensure the smooth operation of fiber laser cutting machines.
The ceramic ring, also known as a laser ceramic ring, is positioned above the nozzle and below the sensor on the laser cutting head (see diagram below). Its primary function is to transmit and collect cutting signals emitted by the nozzle. This safeguards other valuable components of the cutting head against damage caused by nozzle collisions with the material being processed. Additionally, it offers high-temperature resistance and prevents deformation.
A typical ceramic ring consists of three main components:
The ceramic body, stainless steel plate, and copper pillar. Two common materials used for the ceramic body are zirconia and alumina. Zirconia, although more expensive, offers several advantages due to its minimal thermal expansion coefficient (high-temperature resistance), high density (durability), and high electrical resistivity. These properties ensure effective insulation between critical parts and the cutting head, reducing wear and tear on the latter. However, using alumina can reduce costs, although it shortens the replacement cycle for vulnerable parts.
The stainless steel plate serves as a conductor, facilitating the precise and rapid transmission of electrical signals to the copper needle. To maintain its structural integrity at high temperatures, stainless steel plates require specific processing steps; otherwise, they may deform, negatively impacting performance.
The copper pillar acts as a medium, transmitting the electrical signals collected by the stainless steel plate to the internal wiring of the laser head, ensuring flexibility for the controller. Gold plating is often employed to enhance electrical conductivity.
In addition to these components, it's essential to consider conductive silver adhesive, which effectively bonds the three parts together. It remains stable at high temperatures, ensuring consistent electrical conductivity and the safe operation of the laser head. Typically, replacing a ceramic ring does not significantly affect the original laser path and eliminates the need for time-consuming recalibration, although occasional exceptions may require path realignment.
How to Determine When to Replace the Ceramic Ring:
- Inspect the ceramic ring for physical damage.
- Check the connection between the stainless steel plate and the ceramic body for looseness.
- Verify the continuity between the stainless steel plate and the copper needle.
- Ensure that the ceramic ring is not compromised by water or moisture, leading to poor contact.
- Check for any abnormal alarms related to capacitance during air blowing or other anomalies.
How to Replace the Ceramic Ring:
Remove the laser head nozzle.
- Loosen the locking nut of the ceramic ring.
- Remove the old ceramic ring, taking note of the positioning pin and washer locations.
- Insert the new ceramic ring, ensuring that the positioning hole on the ceramic ring corresponds to the positioning pin on the sensor head. Once installed, the ceramic ring should not wobble.
- Tighten the ceramic ring and locking nut, reattach the nozzle, and recalibrate the system. Additionally, perform optical path alignment to prevent beam misalignment.
Material: Imported ceramic + special alloy
Features:
a. Stable signal and high sensitivity
b. High-density ceramic for sensitive copper needle induction
c. Excellent brittleness and temperature adaptability
d. Multiple specifications available (customization based on drawings is also possible)