Differences

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--- lasercutter2 [2019-07-23 22:46] – [Recommended Settings] mirza
+++ lasercutter2 [2025-06-21 20:29] (current) – [Log] simon
@@ Line 11: / Line 11: @@
 {{:large_laser_cutter.jpg?300}}
+See also:
+  * [[lasercutter|Laser Cutter #1]], the machine located opposite Laser Cutter #2
+  * [[lasercutter_tips_and_tricks|Laser cutting tips and tricks]]
+  * [[lasermaterials|Laser materials price list]]
+**Save your project file on the local disk if it's complex otherwise the software will be excessively slow (because the latency of the network share slows down the compile process).**
 ===== Safety =====
@@ Line 19: / Line 25: @@
 {{:flameyboi.jpg?direct&800|}}
+===== Prices =====
+See [[lasercutter#prices]].
 ===== Recommended Settings =====
@@ Line 25: / Line 35: @@
 The test were done in the centre of the cutting bed.
-^ Material ^ Cut Speed ^ Cut Power ^ Notes ^
+^ Material ^^ Cut Speed ^ Cut Power ^ Notes ^
-| Acrylic 1mm | 30 | 40 | Miron |
+^ Acrylic | 1mm | 30 | 40 | Miron |
-| Acrylic 2mm | 28 | 100 | Miron |
+| :::     | 2mm | 28 | 100 | Miron |
-| Acrylic 3mm | 17 | 100 | David |
+| :::     | 3mm | 17 | 100 | David |
-| Acrylic 4mm | 15 | 100 | Miron |
+| :::     | 4mm | 15 | 100 | Miron |
-| Acrylic 5mm | 12 | 100 | Miron |
+| :::     | 5mm | 12 | 100 | Miron |
-| Acrylic 8mm | 4 | 100 | David |
+| :::     | 8mm | 4 | 100 | David |
-| Acrylic 10mm | 3 | 100 | Miron |
+| :::     | 10mm | 3 | 100 | Miron |
-| Ply 3mm | 20 | 100 | Simon |
+| |||||
-| Ply 4mm | 20 | 100 | Miron |
+^ Ply     | 3mm | 30 | 100 | Miron - speed 50 cuts fine, but stutters at curves, 30 is safer |
-| Ply 6mm | 9 | 100 | Miron |
+| :::     | 4mm | 20 | 100 | Miron |
-| MDF 2mm | 30 | 100 | Miron |
+| :::     | 6mm | 9 | 100 | Miron |
-| MDF 3mm | 22 | 100 | Miron |
+| |||||
-| MDF 4mm | 16 | 100 | Miron |
+^ MDF     | 2mm | 30 | 100 | Miron |
-| MDF 6mm | 10 | 100 | Miron |
+| :::     | 3mm | 22 | 100 | Miron |
-| Paper |  |  |  |
+| :::     | 4mm | 16 | 100 | Miron |
-| Card |  |  |  |
+| :::     | 6mm | 10 | 100 | Miron |
-| Engraving Laminate 1.5mm | 50 | 100 | Miron |
+| |||||
-| Engraving Laminate 3mm |  |  |  |
+^ Laminate | 1.5mm | 50 | 100 | Miron |
+| :::                | 3mm |  |  |  |
+| |||||
+^ PTFE (Teflon) | 1mm | 35 | 100 | Mike |
+| |||||
+| Card (200gsm) || 40-55 | 30 | Scott |
+| Card fold line (200gsm) || 100 | 30 | Scott |
+| Paper        ||  |  |  |
 ^ Material ^ Engrave Speed ^ Engrave Power ^ Notes ^
 | Acrylic | 350 | 50 | Miron |
-| Ply | 350 | 50 | Miron |
+| Ply | 500 | 30 | Bart |
 | MDF | 350 | 50 | Miron |
 | Laminate | 350 | 50 | Miron |
+| Card (200gsm) | 500 | 30 | Scott |
 Minimum power setting for the laser to turn on: 19
@@ Line 57: / Line 75: @@
 Before general use:
-  * <del>Create and fit a bracket to hold the air assist tube away from the drive belt
-</del>
-  * <del>Clean laser tube water channels</del>
-  * <del>Test optical power output and calibrate to a sensible maximum (e.g. 66% of peak rating)</del>
-  * <del>Create chart of power/speed settings for common materials (as a basic rule, multiply speeds from the old chart by 3x)</del>
-  * <del>Documentation for existing laser cutter users</del>
   * Update docs:
     * If Z-axis needs to be moved, take care not to crash into the nozzle. Releasing the nozzle locking ring will allow the nozzle to collapse instead of crashing.
-  * <del>**Fix extraction**</del>
-    * <del>Fume extraction is unacceptable at the moment. Fumes or light haze will fill the room. This appears to be caused by fumes re-entering via the window, and not by lack of extraction in the cutter itself.</del>
-    * <del>Possible solution: seal the window properly.</del> Better seals have been installed and the situation is better, but not good enough.
-    * <del>Possible solution: divert the fumes up or down away from the window.</del>
 Soon, but don't wait:
-  * <del>Fit replacement alignment laser (ordered 6th April)</del>
-  * <del>Fit extraction duct mountings on right-hand access door (order delayed, re-sent 10th April)
-</del>
-  * <del>Create spare focus jigs (requires 12mm acrylic, or a new design)</del>
   * Build and install monitoring system (laser usage, temperature logging)
-  * <del>Fully check and adjust alignment</del>
-  * <del>Re-level bed.
-</del>
 Later:
   * Order spares: silicone tubing, <del>mirrors, lens,</del> rotary attachment o-rings
-  * <del>Purchase and install tinted polycarbonate window, 1185x920mm.</del>
+  * <del>Replace broken acrylic cover on front-loading slot.</del> make the two halves of front loading slot not fall off by cutting an extra slot into each of them and adding an extra screw to secure them in the middle
-  * <del>Install vent in G2 door to provide better air flow.</del>
+  * Design and make a better rotary tool
-  * <del>Upgrade internal (to chassis) extraction ducts (use PU ducts instead of foil, merge rear and hopper 100mm ducts into a 150mm duct for egress). Optionally replace flexible door-join with a foam seal. **ACTION: MIKE**</del>
-  * <del>Upgrade cutter-to-blower duct to PU or semi-flexible aluminium 150mm. **ACTION: MIKE**
-</del>
-  * <del>Install ducts to roof and upgrade blower, to avoid releasing fumes onto courtyard users.</del> **ACTION: PETE**
-  * <del>Install LED lighting. **ACTION: ALFIE**</del>
-  * Replace broken acrylic cover on front-loading slot.
 ===== Guide for existing laser cutter users =====
@@ Line 107: / Line 102: @@
   * The enclosure is very large and smoke/fumes take longer to clear. Leave the case closed for 10 seconds after cutting to allow the extraction system to catch up.
   * The air assist is adjustable. Always make sure that it's enabled (on the top control panel) and that the valve (on the right hand side) is open. It's okay to reduce the air assist for delicate materials like paper, but there should always be **some** air flow enabled to protect the lens.
-  * <del>The window is clear. This should absorb the infra-red laser, but it doesn't block much of the visible flash when the laser hits the honeycomb bed. So **don't stare directly at the cutting point**.</del>
   * The window is **tinted as all hell**. This should absorb the infra-red laser and most of the light from the laser. Emphasis on the **should**.
 ===== Checklists =====
@@ Line 180: / Line 174: @@
   * if the temperature doesn't fall then there is probably a fault
   * even if the temperature does fall, **REPORT A FAULT** as the chiller should normally be able to keep up
+===== Other Specifications (for maintenance) =====
+Water tubing: silicone, 12mm OD, 8mm ID, 2mm wall\\
+Chiller: CW-5200\\
+Air assist compressor: Hailea ACO-328\\
+Air assist tubing: silicone, 12mm OD, 8mm ID, 2mm wall\\
+Mirrors: 3x 25mm diameter\\
+Lens: ZnSe, 20mm diameter, 50.8mm focus\\
+Laser PSU: Reci DY20\\
+Laser tube: ZN-1650 (130W rated power, 150W max, 30mA)
+===== Resources =====
+  * {{ :jd90125.pdf | JD90125 manual }}
+  * {{ :lasercut5.3-software_manual-v1.6.pdf | LaserCut 5.3 manual }}
+  * {{ :cw-5000_5200_industrial_chiller_user_manual.pdf | CW-5200 Chiller Manual }}
+  * {{ :cw-5000_5200_industrial_chiller_maintenance_manual.pdf | CW-5200 Maintenance Manual }}
+  * {{ :reci_dy10_dy13_dy20.pdf | Reci DY20 manual }}
+  * {{ :private:20130508-lasercutter-service-report.pdf |Laser cutter service report 2013-05-08}}
+  * {{ :private:jd90125-lasercut5.zip |}} - software supplied with laser cutter
+  * {{ :private:lasercut53-backup-20180315.zip |}} - backup of previous owner's LaserCut53 installation
+  * {{ :mpc6515hardwaremanual.pdf | MPC6515 controller manual }}
+  * [[https://bristol.hackspace.org.uk/wiki/doku.php?id=equipment:a0_laser_cutter:prep|Bristol Hackspace's guide to LaserCut 5.3]]
+===== Access Control =====
+The access control is external to the laser cutter chassis and connected by a CAT5 cable:
+| Orange       | Power 5V              |
+| White-Orange | Power ground.         |
+| Green        | Relay signal          |
+| White-Green  | Relay ground          |
+| Blue         | Current transformer   |
+| White-Blue   | Current transformer   |
+| Brown        | Laser activity signal |
+| White-Brown  | Laser activity ground |
+The tool controller has it's own 5V PSU which is alway-on when the laser cutter is plugged-in.
+An additional relay is fitted in the laser cutter chassis. The relay's coil is energised by the tool controller's 5V power supply, and it's output is in series with the laser cutter's contactor control input. This means that we don't need to route 240V mains into the tool controller enclosure.
+A laser activity monitor is fitted to give the tool controller visibility of actual laser firing. The 5V control input on the high voltage laser PSU is connected, via an optocoupler, to a Raspberry Pi Pico. The Pico tracks the current state of the PSU input  and the accumulated time in microseconds. This data is [[https://github.com/edinburghhacklab/laser-timer-i2c|presented to the tool controller via I2C]].
+{{:0:25-05-31_15-31-16_3152.jpg?direct&200|}}
+{{:0:25-05-31 15-35-41 3153.jpg?direct&200|}}
+{{:0:25-05-31 15-35-45 3154.jpg?direct&200|}}
+{{:0:25-05-31 15-39-22 3155.jpg?direct&200|}}
+{{::laser-activity-monitor-connections.png?direct&200|}}
+Since the photos were taken the optocoupler 5V input is now taken from the laser cutter's controller board USB port. This is avoid false //active// readings during shutdown, where the laser PSU's 5V rail stays active for 8 seconds after losing power.
+Note that the tool controller will also detect an active state based on **attempted** firing of the laser. For example, if the lid is opened during a job the laser will be disabled but the time will still be counted.
+The software is still in an inconsistent state. The laser activity time is displayed on the LCD, and it is used to detect activity, but the values reported on the tool status page will assume 100% duty cycle at 0.5 second resolution.
+Additional monitoring could be added in future:
+  * Temperatures (ambient, coolant out/return, bed, exhaust)
+  * Air-flow
+  * Fume/particulate levels
 ===== Log =====
@@ Line 218: / Line 274: @@
   * Tube #2 (from Smoke and Mirrors) installed. All mirrors realigned to a reasonable (but not perfect) standard. Power level set to 33%.
-===== Other Specifications (for maintenance) =====
+-03-03:
+  * Fettled the rear safety switch for the door to make it work reliably again.
-Water tubing: silicone, 12mm OD, 8mm ID, 2mm wall\\
+-08-08:
-Chiller: CW-5200\\
+  * The mirrors were realigned, the actual laser tube was sitting about 2mm too low and the field was slightly crooked with the top right corner shooting too high. It seems to that the body of the laser had bent back to its original geometry from the time we've got the laser in 2018. It has probably happened due to the different location and maybe better floor. The intermittent issue of the tube switching off could not be replicated, the HV wires were checked but no obvious burn or oxidation marks have been identified.
-Air assist compressor: Hailea ACO-328\\
-Air assist tubing: silicone, 12mm OD, 8mm ID, 2mm wall\\
-Mirrors: 3x 25mm diameter\\
-Lens: ZnSe, 20mm diameter, 50.8mm focus\\
-Laser PSU: Reci DY20\\
-Laser tube: ZN-1650 (130W rated power, 150W max, 30mA)
-===== Resources =====
+-08-05:
+  * "I recently found that pressing the arrow buttons would only "jog" it by a centimetre at a time and I couldn't get it to move continuously while holding it down" (Julian)
+  * "I think the wire harness for the Y axis is troublesome. I think the motor wires are still fine but the limit switch is dead. Also - after jiggerypockering the X axis limit switch wire the issue describes by Julian has gone (it shouldn't but it did). I suggest we get good quality silicone wires, the AWG22 for all signal stuff and 4way  AWG 16-18 for the stepper motors (they are 2A so need more meat) and gather in a group of 2-3 members to rewire the motors, laser pointer and all the limit switches." (Costa)
-  * {{ :jd90125.pdf | JD90125 manual }}
+-11-24:
-  * {{ :lasercut5.3-software_manual-v1.6.pdf | LaserCut 5.3 manual }}
+  * "Both Y and Z axes weren't moving - I spent a while with it tonight and figured out and fixed the Y axis - stepper driver wasn't getting power - but haven't been able to fix Z. It's not the same problem, Z driver is lighting up, it just won't move." (Julian)
-  * {{ :cw-5000_5200_industrial_chiller_user_manual.pdf | CW-5200 Chiller Manual }}
-  * {{ :cw-5000_5200_industrial_chiller_maintenance_manual.pdf | CW-5200 Maintenance Manual }}
+-12-02:
-  * {{ :reci_dy10_dy13_dy20.pdf | Reci DY20 manual }}
+  * "Laser is fixed, the connector that plugs into the motherboard got loose and signal wasn't reaching the driver. Tighten up and homed it. All works fine now. Obviously checked all others too. All cool." (Costa)
-  * {{ :private:20130508-lasercutter-service-report.pdf |Laser cutter service report 2013-05-08}}
-  * {{ :private:jd90125-lasercut5.zip |}} - software supplied with laser cutter
+-05-19:
-  * {{ :private:lasercut53-backup-20180315.zip |}} - backup of previous owner's LaserCut53 installation
+  * "Having an issue with one of the axis (I believe x? The front to back one) was not working after removing the rotary (and obviously resetting the switches to normal position)" (Diarmaid)
-  * {{ :mpc6515hardwaremanual.pdf | MPC6515 controller manual }}
+  * "The laser is fixed, the big switch [that switches between the rotary axis and the normal axis] needs to be looked at in the future." (Costa)
-===== Access Control =====
+-08-09:
+  * PC PSU has failed, swapped with the Old Laser PC (including the CR2032)
+-08-15:
+  * PC replaced - was: Dell Optiplex 980 (labelled "Morrigan"), 4GB RAM, HDD; now: i5-8400T, 16GB RAM, 256GB NVMe
-The access control unit will be external to the laser cutter chassis and connected by a cable:
+-10-18:
+  * Top cover hinges modified
-  * GND
+-10-27:
-  * 5V supply (from laser cutter, always on)
+  * Lens is clean
-  * Enable power-up (open drain)
+  * Mirror cleaned
-  * Current clamp A
-  * Current clamp B
-  * (additional pins may be required for better active/idle detection)
-===== Monitoring =====
-An external unit will contain an ESP8266 and LCD. It will connect to the main chassis by cable:
+-02-22:
+  * Guide laser is not working
-  * GND
+-04-26:
-  * 5V supply (from laser cutter, always on or switched)
+  * External extraction fan moved from active RCD plug to passive RCD socket
-  * One wire bus for DS18B20 temperature sensors
-  * I2C SDA
-  * I2C SCL
-  * Laser enable pin
-  * Laser power level pin
-  * Laser powered-up signal?
-  * Laser cutter in use signal?
-The monitoring device will:
+-05-31:
+  * Active time monitoring connected to the tool controller
+  * Guide laser ground wire was broken in two places, repaired and aligned
-  * Log laser tube time
+-06-13:
-  * Log temperatures (ambient, coolant out/return, bed, exhaust)
+   * Guide laser doesn't work in certain positions, the wires need replacing
-  * Detect cutting sessions and report the most recent on the LCD
-  * Potentially, log fume/particulate levels
 {{tag>equipment}}