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Introduction and application of 3D fiber laser cutting robot
**1. Overview**
The 3D fiber laser cutting machine is a highly advanced system that integrates a specialized fiber laser cutting head, a high-precision capacitive tracking system, a fiber laser source, and an industrial robot. This equipment enables flexible and multi-directional cutting of metal sheets with varying thicknesses, making it ideal for complex 3D workpieces. It is widely used in industries such as metal processing, machinery manufacturing, and automotive parts production.
**2. Three-Dimensional Fiber Laser Cutting Robot**
**(1) Principle of 3D Laser Cutting**
Once the laser is generated, it is directed through mirrors and focused onto the material using a collecting lens. The intense heat from the laser causes rapid melting or vaporization at the point of contact, allowing precise cutting along the desired path. This method ensures accuracy and efficiency during the cutting process.
**(2) Selection of Optical Fiber**
The choice of fiber laser power depends on the thickness of the metal sheet being cut. Common power levels include 200W, 300W, 400W, 500W, and 1000W. Each laser is paired with an appropriate cooling system to maintain stable operation. Additionally, the length of the fiber cable is selected based on the robot's reach and the size of the workpiece, ensuring optimal performance and customer satisfaction.
**(3) Requirements for Auxiliary Gas**
High-purity oxygen (99.99%) is typically used as the auxiliary gas in 3D fiber laser cutting. This enhances cutting precision, speed, and the quality of the cut surface, making it essential for achieving clean and accurate results.
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**3. Features of 3D Fiber Laser Cutting Robot**
**(1) High Flexibility**
This system is particularly well-suited for small-batch and custom 3D sheet metal cutting. Its flexibility is evident in two key areas: first, it can cut almost any type of metal plate using CNC programming; second, the cutting path can be easily adjusted by modifying the program, eliminating the need for expensive dies. This makes it a cost-effective alternative to traditional trimming and punching tools.
In addition, the absence of direct mechanical force during laser cutting simplifies jig design and reduces setup time. With the right hardware and software, a single laser system can perform multiple functions, enhancing productivity and versatility.
Overall, 3D laser cutting improves product quality, increases efficiency, shortens development cycles, and reduces labor costs. Despite the initial investment, many automotive and aerospace manufacturers in China have adopted this technology, and research institutions are also exploring its potential.
**(2) Advantages and Disadvantages of Fiber Laser Cutting Robots**
Using industrial robots instead of five-axis machines offers cost savings and improved flexibility. While the repeatability of robots is slightly lower (around ±100μm), it still meets the needs of the automotive industry.
Fiber lasers offer better cutting quality, lower energy consumption, and easier integration with robots. However, they are limited to metal materials due to their 1064 nm wavelength, which is not efficiently absorbed by non-metals.
Combining robots with fiber lasers allows for one-step processing, reducing the need for post-processing and lowering both labor and mold costs. Offline programming software further streamlines the process, making it ideal for small batches and custom orders.
The system also features advanced control systems, intelligent manipulators, and imported laser heads that ensure high-speed, high-precision cutting. These components work together to maintain focus and stability, even when dealing with difficult materials like stainless steel.
**4. Technical Advantages of 3D Fiber Laser Cutting Robot**
**(1) Advantages of 3D Cutting System**
- Twice the cutting speed compared to similar systems.
- High positioning accuracy up to ±100μm.
- Capable of cutting circles smaller than φ2mm in under 2 seconds.
- A 2.01m arm can handle both 2D and 3D cutting within a 3m diameter sphere.
- Offline programming software allows for quick and easy trajectory generation from 3D models.
**(2) Performance of IPG Fiber Lasers**
IPG fiber lasers provide stable output, excellent beam quality, and compact design, offering significant advantages over traditional gas and solid-state lasers.
**(3) Import Laser Cutting Head**
Imported laser heads ensure precise focusing, avoiding issues caused by uneven material surfaces. They can withstand high-pressure gas, improving performance on challenging materials.
**(4) Robot Control System**
The robotic control system delivers high reliability, speed, and precision, with optimized motion control software that improves efficiency and reduces cycle times.
**5. Application of 3D Fiber Laser Cutting Robot**
**(1) RX160 B-Pillar Cutting**
- High-precision cutting of outer frames and holes.
- Fast cutting speeds reduce thermal deformation.
- Flexible programming adapts to different products.
- Cost-effective solution for high-volume applications.
**(2) RX160 Engineering Machinery Sheet Metal Cutting**
- 3D cutting of large sheet metal parts.
- Large working range suitable for multi-station cutting.
- Twice the speed of traditional five-axis machines.
- Compact and rigid robot design reduces gantry costs.
**6. Conclusion**
In the future, 3D laser cutting technology will continue to evolve toward higher precision, speed, flexibility, and integration. Although China has made progress, there are still gaps in high-power laser development and theoretical research. Compared to foreign technologies, China lags in areas like beam quality and deep understanding of laser-material interactions. Therefore, continued research and development are essential to close these gaps and fully realize the potential of 3D laser cutting in the manufacturing sector.