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Robotic Laser Cladding System
The robotic laser cladding system is an advanced metal‑surface additive‑manufacturing equipment with a 6‑axis industrial robot as the motion actuator. It integrates fiber laser, coaxial powder‑feeding unit, cooling module and integrated control system. Leveraging the excellent multi‑degree‑of‑freedom motion capability of the robot, it performs laser cladding reinforcement and wear repair for complex‑curved and special‑shaped parts such as shafts, rollers, molds and impellers. It is widely applied in equipment remanufacturing, mold repair, mining, metallurgy, power, petrochemical and other industries.
Technical Features
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- Flexible Processing by 6‑axis Industrial Robot: The 6‑axis industrial robot delivers high‑degree‑of‑freedom motion for multi‑angle cladding on complex curved surfaces and special‑shaped cavities. Combined with rotary positioner worktable, it adjusts workpiece posture to realize all‑direction processing for large and irregular components.
- High‑performance Laser Optical Unit: Equipped with high‑power fiber laser and coaxial powder‑feeding cladding head. It delivers stable laser spot and excellent powder convergence. Cladding layers form metallurgical bonding with substrate, featuring small heat‑affected zone and low workpiece deformation. Optional nozzles including 3‑way, 4‑way and annular nozzles are available for diverse cladding‑width requirements.
- High‑precision Stable Powder‑feeding System: Dual‑hopper powder feeder with stepless adjustable rotating speed and high powder‑feeding repeat accuracy. Compatible with iron‑based, nickel‑based, cobalt‑based and other metal powders. Argon or nitrogen is adopted as carrier & shielding gas to guarantee cladding quality.
- Integrated Control System: Industrial‑bus control realizes interlocked operation of laser source, robot, powder feeder and water‑chiller & gas circuit. It supports offline programming and imported machining paths. Functions include process‑formula storage, real‑time status monitoring, fault alarm and log export for low‑threshold operation.
- Comprehensive Safety Protection: Fully‑enclosed protective sheet‑metal housing with observation windows for laser safety protection. Equipped with three‑color status indicator lamps and emergency‑stop protection. Full‑link monitoring for gas‑circuit pressure, water temperature and laser status ensures production safety.
- Modular Expandable Design: Optional infrared closed‑loop temperature‑control module and molten‑pool visual‑monitoring unit for real‑time temperature monitoring. Laser power, robot payload and worktable configuration can be customized upon request.
Main Equipment Configuration
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| Sub‑system | Component Name | Configuration Description |
|---|---|---|
| Laser Generating Unit | Fiber Laser | 3000 W fiber laser; wavelength 1080±10 nm; power adjustment 10‑100%; LOE fiber interface; stable short‑term & long‑term power output |
| Optical Processing Unit | Laser Cladding Head | Coaxial powder‑feeding cladding head, max. withstand power 4 kW; LOE fiber interface; optional 3‑way / 4‑way / annular powder‑feeding nozzles |
| Motion Actuating Unit | 6‑axis Industrial Robot | 6‑axis robot with repeat positioning accuracy ≤±0.06 mm, large working radius for complex spatial trajectory movement |
| Rotary Positioner Worktable | Rotary worktable for workpiece posture adjustment to realize circumferential and multi‑angle cladding | |
| Powder Feeding Unit | Dual‑hopper Powder Feeder | 220 VAC power supply; applicable powder granularity 20‑200 μm; stepless rotating speed 0‑20 r/min; powder‑feeding repeat accuracy ＜±2%; independent PLC control; argon / nitrogen as carrier & shielding gas |
| Cooling Unit | Industrial Water Chiller | Circulating cooling for laser and cladding head; temperature‑control accuracy ±0.5 ℃ to ensure heat dissipation for long‑duration continuous production |
| Control Unit | Integrated Control System | Industrial‑bus control for laser, robot, powder‑feeder and gas‑circuit interlock; support offline programming, process‑formula storage, fault alarm and log export |
| Accessory Kit | Spare‑part Kit | Protective lenses, laser‑safety goggles, complete gas‑water pipelines and connectors |
Equipment Performance Specifications
| Item | Specification |
|---|---|
| Model | Robotic Laser Cladding System |
| Process | Laser cladding (laser hardening expandable) |
| Rated Laser Output Power | 3000 W (6000 W customizable) |
| Laser Wavelength | 1080±10 nm |
| Motion Mechanism | 6‑axis industrial robot + rotary positioner worktable |
| Robot Repeat‑positioning Accuracy | ≤±0.06 mm |
| Powder Feeding Rate | 1‑150 g/min |
| Powder‑feeding Repeat Accuracy | ＜±2% |
| Applicable Powder Granularity | 20‑200 μm |
| Total Power Supply | 380 V three‑phase, 50 Hz |
| Cooling Mode | Water circulating cooling |
| Shielding / Carrier Gas | Argon, nitrogen, supply pressure ≥0.5 MPa |
| Max. Endurable Power of Cladding Head | 4 kW |
| Applicable Powder Materials | Iron‑based, nickel‑based, cobalt‑based, copper‑based alloy powders |
| Programming Mode | Teach‑in programming, offline‑program import |
| Communication Protocol | EtherCAT / Modbus |
After‑sales Service
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- Warranty Terms: 1‑year whole‑machine warranty; laser source follows manufacturer’s standard warranty. Free software upgrades within warranty period; free replacement for non‑human‑damaged components.
- Fault Response: Remote technical response within 2 hours upon fault report; on‑site troubleshooting by engineers available for major failures.
- Technical Training: Comprehensive on‑site training after commissioning, covering machine principle, robot teach‑in programming, parameter setting, powder handling and routine maintenance, enabling independent operation by operators.
- Spare‑part Supply: Sufficient stock of consumables such as protective lenses and nozzles. Favorable spare‑part purchasing channels are provided after warranty expiration.
- Long‑term Technical Support: Continuous technical consultation for new‑material and new‑process debugging. Complete electronic and printed operation & maintenance manuals are delivered.
