During the Chinese New Year holiday,lasers may face risks such as low temperature,high humidity,dust accumulation and unattended operation,which may cause optical lenses to be damp,cooling systems to be frozen,and mechanical structures to be corroded.This may not only affect the resumption of work after the holiday,but also increase maintenance costs and shorten equipment life.In order to ensure the stability of the equipment during the shutdown and the rapid resumption of production after the holiday,this maintenance guide is developed.
This guide is aimed at the operating and holiday environment characteristics of industrial lasers (including solid, fiber and other mainstream types),covering shutdown preparation,shutdown operation,holiday maintenance and post-holiday resumption of work,clear operation standards for all links,provide scientific and feasible maintenance basis for relevant personnel,and help achieve safe shutdown and efficient resumption of work.
01 Preparations Before Downtime
(completed 3 days before the Spring Festival holiday)
(1) Verification of the condition of equipment
- Parameters record:record laser operation parameters,such as output power,spot quality,cooling system temperature,etc.Confirm no abnormal alarm before stopping the process.
△ Laser Operation Parameters
- Optical path inspection:Inspect the status of external optical path devices,such as beam expanders,mirrors,DOE,galvanometers,and field lenses for dirt,scratches,or loosening.
- Troubleshooting:If there are minor problems such as noise and parameter fluctuation,maintenance should be completed before shutdown to avoid holiday failure.
(2) Preparation of materials and tools
- Consumables and spare parts:Consumables and spare parts should be prepared,such as anhydrous alcohol,lens paper,non-dust cloth,dust canister,sealing film,anti-rust oil (for mechanical parts),drying agent,etc.
△ Conservation Consumables (Hydro-free Ethanol and Dust Cloth)
- Safety equipment:Prepare protective equipment and tools such as goggles,insulating gloves,anti-static wristband,wrench,screwdriver,etc,to ensure safe operation.
(3) Environmental pretreatment
- Site Cleaning:Remove all debris around the equipment to keep the working area clean and dry to avoid dust accumulation.
- Environmental control:Check the temperature and humidity of the machine room to ensure that the temperature is controlled at 15-25 ℃ and the humidity is ≤ 60%.If the environment is humid,it is necessary to open the dehumidification equipment in advance.
02 Downtime Operations Process
(Enforcement 1 day before the Spring Festival holidays)
(1) Steps of gradual downtime
- Turn off laser output:Click the “laser switch” button in the upper computer software interface,wait for the laser to completely turn off(the button turns gray),keep the water cooler and other auxiliary systems running for 5-10 minutes,and then cut off the main power.
- Cut off the load power supply:①Close the laser power supply;②Turn off the refrigeration system switch;③Turn off the power supply to the refrigeration system;④Close the main power supply.
- Turn off the main power supply:After confirming that all subsystems are stopped,turn off the main switch of the equipment and unplug the power plug(long-term shutdown is recommended)to avoid standby power consumption or lightning risk.
△ Turn Off the Laser Power Supply
(2) Cooling system maintenance
- Water-cooled laser:Discharge the coolant in the cooling tank(or add antifreeze, when the ambient temperature is below 0 ℃,it is recommended to add antifreeze,the ratio is 2: 8,that is,20% antifreeze + 80% deionized water;When the ambient temperature is less than -10 ℃,it can be increased to 30%),rinse the water tank and pipes with deionized water, dry and seal the water tank interface;
- Air-cooled laser:clean the air-cooling fan to remove dust blockage.
△ A chiller
(3) Safety and protective measures
- Warning sign:Post a conspicuous sign at the power supply of the equipment ” No closing switch during Spring Festival maintenance ” to avoid misoperation.
- Cable arrangement:Arrange equipment cables to avoid pressure and bending and properly store power plugs.
- Fire confirmation:Check the fire facilities in the engine room and confirm that they are in a normal and usable state to ensure there are no safety risks.
△Fire Fighting Equipment
03 Maintaining During Spring Festival Holidays
(Remote / Regular Patrol)
(1) Environmental monitoring
- Regular inspection:arrange personnel to inspect the machine room 1-2 times a week to check whether the temperature and humidity are up to standard(avoid the temperature of the machine room below 5 ℃ in winter to prevent equipment parts from freezing)and whether there is water leakage.
- Closed dustproof : Ensure that the door and windows of the machine are closed tightly to prevent dust,mice and insects from entering the equipment.
(2) Equipment protection
- Authorization management:non-authorized personnel are prohibited from contacting the laser.No one is allowed to turn on or disassemble the equipment.
- Extreme weather response:In case of extreme weather(such as cold wave , heavy rain ),increase the frequency of inspection,and deal with environmental abnormalities in time.
04 Resumption of Work Inspection and Start-up Process
(Deal with it before returning to work after the holiday)
(1) Preparations before returning to work
- Environmental restoration:remove the sealing film and protective cover on the equipment surface and clean the surrounding environment of the equipment to ensure that there are no debris and dust.
- Appearance inspection:Inspect the appearance of the equipment and confirm that there are no loose or damaged parts;Cable connection is normal.
(2) Step-by-step machine inspection
- Start the cooling system:First,check the water cooler and the ambient humidity,adjust the temperature of the water cooler (control according to the equipment requirements),check whether there is leakage in the cooling system pipeline , start the cooling cycle , and confirm that the water temperature is stable in the normal range(usually 20-25 ℃ ).
- Power restoration:connect the power plug,turn on the main power,observe whether the power indicator of the equipment is normal and there is no abnormal alarm.
(3) Equipment debugging and trial operation
- No load test:start the control system to run no load,check whether the laser and the moving parts are running smoothly and without noise.
- Parameter calibration:Test laser output power, spot quality,and compare with the parameters recorded before shutdown to ensure the deviation is within the allowable range;If the parameter is abnormal,adjust it in time or contact the after-sales service.
- Load verification:Select a small number of trial machining workpieces to carry out actual machining tests to verify whether the laser processing accuracy and stability are normal,and confirm that there is no problem before returning to normal production.
Appendix Note
- Start the water chiller first:Before starting the laser,make sure the water chiller has been running stably for 5-10 minutes,so that the cooling water circuit can fully circulate and take away the residual heat in the pipeline,and then start the laser to avoid cold and hot shock damage to the equipment.
- Strictly abide by the rules:The maintenance operation must strictly abide by the requirements of the equipment manual,and shall not illegally disassemble the resonant cavity,pump source and other core components.In case of complex failure,timely contact the manufacturer after-sales processing.
- Safe storage:Non-aqueous ethanol , anti-rust oil and other consumables should be stored properly , away from fire sources and laser operation areas.to prevent safety accidents.
- Record keeping:All maintenance,inspection and start-up operations shall be recorded in writing for follow-up tracking of equipment status.
