Requirement specification: Integrated Micro Laser Spot Welder with twin workstations
Compliance matrix
For each of the specification/feature asked, You should give details of the specification offered, exact values, make and model of items, brochures etc. as applicable. You have to respond to the above clarifications point-by-point and not by single statement ‘complied’
1 / Scope of supply / Complied / Not complied / RemarksThis micro spot welder is intended for the spot welding of fine metallic wires to terminal pins. The system shall be capable of welding NICHROME (80:20) wires of sizes ranging from 0.04 - 0.10 mm diameter to stainless steel (AISI 304) pin of diameter 0.90 mm.
Scope of supply includes: One laser system (Pulsed Nd:YAG, solid state, flash pumped and air cooled), Real time power feed back, pulse shaping with I/O controller connecting twin workstations operating on time-share mode.
Twin workstation system: Each workstation shall be with Class-1 safety enclosure with vertical pneumatic front access door, XYZ stage CNC system, focus head & optics, viewing system, cover gas module, etc. All functions required for spot welding operation like focusing, alignment, beam triggering, shield gas flow, etc shall be integrated into the micro processor control. Each workstation shall incorporate separate Power/Energy monitoring meter and provision for passing of inert gas through a weld box that holds the job.
The Laser system with twin workstations has to be supplied, installed and commissioned at our site (with performance test and job prove out). After installation of the machine at our site, an extensive training on the operation, application software and basic maintenance has to be provided.
2 / Machine configuration
2.1 Laser system configured with I/O controller connecting twin workstations operating on time-share mode
2.1.1 / Laser type / Air cooled, pulsed Nd:YAG laser power supply
2.1.2 / Laser wavelength / 1064 nm
2.1.3 / Average power / 25 W
2.1.4 / Peak Power / 6 kW
2.1.5 / Pulse energy / 25 joules
2.1.6 / Pulse duration / 0.2 - 10 ms, programmable variable
2.1.7 / Repetition rate / Variable up to 30 Hz
2.1.8 / Real time power feedback control and pulse shaping / Real time power feedback control and pulse shaping for ensuring stable pulse to pulse energy. In pulse shaping fixed and variable mode (up to 20 segments) should be provided.
2.1.9 / Pointing laser / Diode aiming laser
2.1.10 / Configuration of Time
share output and beam delivery / Time share fiber output : 2 Nos
Stepped index fiber : 2 Nos.
Core diameter of fiber cable : 200 micron (Approx)
Length of fiber cable should be 5 m (minimum)
Provision for additional output for future expansion to be provided in the laser system
2.1.11 / Time share specification / Time share system should allow one laser to be used with two workstations. The controller should handle all safety signals and schedule selection and laser control. With time sharing one laser should support two workstations using different weld schedules. The safety interlocks should prevent laser from firing into a workstation if its door is open. The two operators should be able to work independently without necessity for communicating each other.
2.2 LASER WELDING WORKSTATION – 2 UNITS : The two identical workstations each having Class-1 safety enclosure, job manipulation system, focus head, optics & viewing systems and inert gas system.
2.2.1 / Features of welding enclosure / Size of safety enclosure (Class-1 eye safe enclosure) : Manufacture specified to suit the CNC system.
Vertical pneumatic front access door, Nd:YAG safety viewport
(500 x 350 mm approximate), safety interlocks, and fume extraction port
2.2.2 / Features of CNC System. / Laser Welding Workstation having a 3 axis motion system with the following features:
CNC table size : 500 mm x 500 mm or nearest
XY stage assembly (400 mm x 300 mm) with tool plate on top, Feed system : Pre-tensioned ball screws with preloaded nut
Feedback system: Closed loop with encoders.
Encoders on drive motors and Sinusoidal drive motors.
15 mm (Approx.) thick aluminum base plate to be provided on the CNC bed for mounting jobs.
Overhead gantry mounting; welded steel supports
150 mm or higher Z stage mounted to gantry, ACME screw
CNC system should have the following:
Three (3) axis motion control system, Linear interpolation in 3 axes and Circular interpolation G/M code programming (NC Programming function), Program memory, HMI Software; integrated motion and Integrated Laser controls, laser communications (Laser operation through CNC program)
Program execution in Auto mode, Manual / MDI mode operation.
2.2.3 / Focus head, Optics and viewing systems / The system should have a CCTV Focusing Assembly , Tip-tilt camera adjustment, 30 mm diameter optics with 125 mm collimating and 60 mm output focal lenses. Lens combination of producing 100 micron focused spot diameter.
Mount focusing assembly and camera to Z stage
Variable intensity LED ring illuminator should be attached
around the focus lens mount
2.2.4 / Black & white CCTV
camera system / This includes high quality camera, CCTV monitor (23” or nearest),Cross hair generator and Interconnecting cables. The magnification of camera should be 100x (minimum)
2.2.5 / PC system details / Latest PC with LED monitor (23” or nearest), keyboard, mouse etc.The PC shall be delivered with two spare hard disks which shall be used as a backup with the identical image as standard hard disks. PC monitor and CCTV monitor should be ergonomically positioned for easy operation.
2.2.6 / Image capturing features / Video capture board for viewing of still/motion image of the job to be provided. Provision should be there to capture CCTV image duringwelding.Provision for data logging to capture actual laser settings immediately after each weld. File format is *.CSV/latest format
2.2.7 / External control pendant / The external control pendant should have the following features:
- Precision type ratchet wheel mechanism for XYZ axis movement in continuous/incremental mode for job manipulation.
- Provision for selecting Feed rate of XYZ axis through a knob with stepped increment (0.01, 0.1 1 mm..)
- Control for Program Run, Laser active/deactive, manual cover gas on/off, Emergency stop etc.
2.2.8 / Laser Energy meter / Reputed make Laser power meter suitable for this Nd:YAG laser system. The meter should contain sensor unit mountable on XY table and a hand held display unit. The meter should have provision for selecting laser power or energy (Settable range: lower range should cover less than 1J). The meter should have provision for automatic power check and data logging. Party should clearly mention the model and make of the laser power meter in their quote.
2.2.9 / Features of Inert gas
system (Cover gas module) / Weld samples/jobs are to be positioned inside a metallic box having cover glass at top (Size of weld box: 160 mm length x 160 mm breadth x 60 mm height) and with provision of inlet/outlet of inert gas. This metallic box is to be mounted on CNC table. Shielding gas has to be fed to this box, ensuring gas flow while welding takes place. This weld box will be supplied by us.
Gas flow interlock provision to be provided to prevent firing of the laser if cover gas is not flowing through this box. Flow meter, solenoid, inside ducting and nozzle for connection to fume exhaust system etc. to be incorporated.
2.2.10 / General features / Machine base with casters and leveling feet. The height between ground floor to top surface of CNC table should be 800 mm approx.
3 / Spares
3.1 / 2 sets of spares kit (Laser system) for maintenance to be provided
4 / Safety features
Workstation to comply with all requisite safety features with respect to electrical, radiation, interlocks etc. Safety goggles to be supplied along with the workstation.
TERMS AND CONDITIONS: Integrated Micro Laser Spot Welder withtwin Work Stations
1 / Other conditions and requirements1.1 / You should have sufficient expertise and know-how in the manufacture of such equipment and this shall not be a fresh development.
1.2 / Overall space requirement for installation and operation of the machine including control panel, computer etc. should be given along with machine layout diagram, weight and size of the heaviest module to be handled during installation.
1.3 / All bought out items used in the totalsystem should be sourced from reputed manufactures/suppliers.
2 / Guarantee
Guarantee shall be given for all the items in the scope of supply, for a period of minimum 24 months after installation and commissioning. Any defect observed during the guarantee period will have to be repaired/replaced free of cost. For optics (like lens) which are glass items, guarantee shall be given except for damage due to mis-handling. All the software updates during the guarantee period shall be supplied and installed on real time basis, free of costs. Any licensed software used in the workstation should be supplied to VSSC along with the license. An image of the System Hard Disk to be supplied to VSSC to put back the system into operation during a HDD Failure.
3 / AMC
You should be able to provide Annual maintenance Contract (AMC) and support for spares for the equipment for 10 years after the expiry of warranty period as per standard terms & conditions of VSSC.
4 / Pre-delivery inspection and training : The pre-delivery inspection and training should be at your site during which the following requirements shall be met:
4.1 / Performance test of the total laser system should be carried out at party’s site in the presence of our representatives. The workstation has to be fully assembled and erected for this purpose. It should meet all the technical specifications given in Sl.No. 2 above. The work station shall be inspected as per standard protocols. Demonstration of safe and reliable operation of the complete laser welding system prior to delivery. This includes functional test of electrical, optical, mechanical, pneumatic, software and demonstration of Performance Criteria. Laser shall be calibrated for power/energy and beam quality. Manipulator shall be calibrated for position & geometry as per standard test chart.
4.2 / Job prove out : Enough specimens shall be welded to prove the capability, consistency and reliability of the total laser system. Sufficient weld samples and fixtures/tooling will be supplied by VSSC free of cost.
4.3 / Training to our representatives for the following.
i.)Time share mode operation of the machine specific to the welding of the fine nichrome wire to terminal pin joint. This includes functional operation of Laser power system, CNC system, real time power feedback system, optics system, power monitor and other sub system.
ii.) Maintenance and trouble shooting.
5 / Installation and commissioning
The Micro Laser Spot Welding twin Work Stationsshould be installed and commissioned at our site by the party. All performance test should be carried out for all technical specifications as mentioned in Sl.No. 4.1 and 4.2 of terms and conditions.
6 / Training
Training should be provided by your personnel at our site after installation and commissioning of the machine. The training should cover general operation, CNC programming, setting operation for a spot welding, operation of the accessories and sub systems supplied with workstation, and basic maintenance of the workstation.
7 / Documentation: Two sets of the following documents shall be supplied along with the machine:
- Operator manual, Programming manual
- Spare parts list, Maintenance manual & diagnostic software for maintenance purpose.
- Detailed Circuit diagram of all PCBs
- Details of the performance test and Laser calibration / QC check documents
- Preventive maintenance check list, trouble shooting charts and guidelines
- Documents of all bought out items, Technical literature/catalogue (in English) illustrating the operation and maintenance of the Laser system, workstation and other systems should be forwarded along with the machine.
- Metric system of measurement should be used in the system documentation, specifications drawings, manuals etc.
8 / LD Clause:
The Delivery Date mentioned in the Contract/order will be the essence of the Contract. You shall strictly adhere to the delivery schedule mentioned in your quotation. Otherwise LD will be applicable as follows :
"LIQUIDATED DAMAGES:” The delivery period quoted by you and stipulated in the Purchase Order shall be deemed to be the essence of the order and delivery must be completed not later than the date specified therein or otherwise VSSC shall have the right to recover a sum @ 0.5% of the order value per week or 0.5% of the value of the stores for which the delivery is delayed for each week of delay, as the case may be, subject to a maximum of 10% of the order value”. [Mandatory]
9 / Performance Bank Guarantee:
In the event of placement of order, you have to submit a Performance Bank Guarantee for 10% of the order value, obtained from a Nationalised/Scheduled Bank, which shall be valid beyond 2 months from the expiry of Guarantee/Warranty period. [Mandatory]
10 / Security Deposit: In the event of placement of order, you have to submit a Security Deposit by means of a Bank Guarantee/Fixed Deposit Receipt for 10% of the order value, along with your Order Acceptance. The Bank Guarantee/FD Receipt shall be valid beyond two months of the stipulated Delivery Period/Completion period and completion of all contractual obligations by you. The Security Deposit will be returned to you without any interest within one month after the stipulated delivery period/completion period and completion of all contractual obligations. [Mandatory]
11 / Payment Terms:
Payment Terms (in Indigeneous case): Our normal payment terms is “within 30 days after receipt/installation and acceptance of item at our site”.
Through bank: If you insist for payment through Bank, only a maximum of 90% of the order value/item value can be accepted through bank. Balance 10% will be made within 30 days after receipt/installation and acceptance of item at our site. Also pl. note that all bank charges will be to your account. The documents can be negotiated through our banker, M/s.SBI, Thumba branch and prior intimation shall be given to our Accounts Officer, PRSO Accounts, VSSC, Thiruananthapuram-695022.
Payment Terms (in Import case): Our normal payment terms are Sight Draft.
Through bank: If you insist for LC payment, please note that all bank charges will be to your account. The documents can be negotiated through our banker, M/s.State Bank of India, Thumba branch, Kerala, India and prior intimation shall be given to our Accounts Officer, PRSO Accounts, VSSC, Thiruananthapuram-695022.