Laser CutterLab 14: Flat Project Example

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Lab Goals

Review previous relationships and settings in Appendix

  • Understand why settings are made

Review symbolic conventions to enhance explanations

Perform initial physical setup

Create Rotary Attachment Configuration Settings

Post-Lab Assignments

  • Document relationships not previously understood in Appendix

Pre-lab / Lab readings

Laser Cutter Manual: Scan through content

BobCam Users Manual: Scan through content

Equipment needed

Laser Cutter

Computer

USB Cable

Laser Cutter Software

Laser Cutter Manual

Laser Cutter Lab 1 Datasheets

black or dark blue pen (pencil optional)

additional sheets for Appendix entries

Parts needed

none

Lab safety concerns

Follow safety standards presented in Lab 1

Machine can start and stop without warning, keep clear

1. Symbolic Conventions to enhance Explanations

  1. “text“ denotes instructions
  2. Bolddenotes labels given to control text boxes
  3. [data] denotes data to be input by user into either a software text box

or selected on the machine control panel

  1. labeldenotes key or menu item to be selected
  2.  denotes software push-button
  3. denotes arrow keys on the machine control panel
  4. denotes checkbox status

2. Physical Setup

  1. Obtain the following:
  2. Keys for control panel
  3. Calibration plate (laser focus calibrated for thickness of plate)
  4. USB software dongle (plugged into Laser Cutter computer)
  5. Verify that ALL Laser Cutter cabinet doors are closed and locked
  6. Verify that ALL Laser Cutter axis control cables are plugged in and secure
  7. May have been disconnected from previous rotary operations
  8. Remove all materials from bay working surface
  9. Clean and vacuum bay area if debris is present
  10. CAUTION: objects in BAY can damage laser optics during homing operations (automatic movements to origin)
  11. Laser Gantry AUTOMATICALLY moves to home position (origin) when control panel KEY is turned on
  12. Distilled water in chiller filled to about 1” from fill tube
  13. Chiller connected to laser cutter
  14. DANGER: Laser will BURN OUT within 30 seconds without chiller running
  15. Water temperature must be less than 35 C degrees before energizing laser; WAIT for water to cool down to less than 30 C degrees
  16. Shutdown laser if temperature rises to 35 C degrees
  17. Troubleshoot system to fix related causes
  18. Plumbing connections input to output, and output to input
  19. Chiller electrical connection plugged into Laser Cutter
  20. Air Compressor connected to laser cutter
  21. CAUTION: Final optics lens will be damaged without air supplied
  22. Air hose connected
  23. Air Compressor electrical connection plugged into Laser Cutter
  24. Ventilation filter system assembled and connected to Laser Cutter
  25. CAUTION: Laser mirrors will burn out without ventilation running
  26. Ventilation blower requires 110 VAC
  27. DANGER: Connecting Ventilation filter system to 220 VAC will destroy related electrical components
  28. Turn On Ventilation blower
  29. Check filter differential pressure gage not in RED zone
  30. Change filter media if in RED zone
  31. Computer connected via USB connections
  32. Turn On computer
  33. Install Laser Cutter Software dongle in available USB port
  34. Laser Cutter software loaded onto computer and operating
  35. Optionally
  36. AutoCad 2004 is loaded on computer
  37. Laser Cutter software with AutoCad toolbar add-on loaded
  38. 220 VAC connected to Laser Cutter
  39. DANGER: The Laser Cutter comes standard with a 110V plug installed to provide electrical power; the Laser Cutter requires 220 VAC to operate
  40. At the earliest opportunity, replace the 110V plug with an approved 240 VAC plug and socket
  41. Always use a grounded power source
  42. Flip switch, or otherwise provide 220 VAC power to Laser Cutter
  43. Turn on computer
  44. Insert Key into control panel and turn system on
  45. Actuate Emergency Stop
  46. Rotate Emergency Stop knob to reset Emergency Stop

3. Sample Flat Project

  1. Open Jamieson software and create a 1” x 1” square box
  2. Shading has no effect upon the laser
  3. Save file as proj1.mol
  4. Follow the above Physical Setup
  5. “Chiller already running”
  6. “MachineON and Reset, and Computer ON with Jamieson software running”
  7. “Machine control panel key already turned ON”
  8. “Laser gantry already positioned at origin (back right corner)”
  9. “Ventilation system already running”
  10. Plug machine USB cable into Computer USB port
  11. “System ready for operation”
  12. either from control panel or from computer
  13. From computer with proj1.mol open
  14. <download>
  15. Job File (proj1.mol) is already loaded into the machine Control Panel
  16. [Go to machine]
  17. > to select Job File to be run (proj1.mol)
  18. Ensure Honeycomb bed is installed
  19. <Z>
  20. > “Bring bed up to bottom of bed opening (helps align honeycomb)
  21. Lay honeycomb bed in place
  22. > Move bed down so product (project raw material) at its high point will fit under laser cutting lens without making contact
  23. Place Calibration Plate on top of product
  24. <Z> to exit Z-axis move
  25. <ESC> “nothing highlighted”
  26. > Jog Laser in X and Y axi to position laser over product and calibration plate
  27. <Z>
  28. <RESET> “table moves up automatically to correct focus distance for laser”
  29. <Z>
  30. [Remove Calibration Plate]
  31. Put Calibration Plate in a secure location where it will NOT be damaged
  32. Calibration Plate is a precisely known thickness so the laser focus will be at exactly the bottom of the plate when auto-focus is performed
  33. Calibrate product position
  34. Arbitrarily choose a convenient location for the product to be cut
  35. Near the front and center of the machine
  36. Easy to watch, easy to manipulate
  37. Option 1: Put straight edge of your product under red dot
  38. Use  arrows to see that laser red dot tracks along edge of product
  39. adjust product accordingly
  40. Option 2: Use known flat and stiff material and place along Y-axis gantry and on the worktable
  41. This creates a straight edge on the worktable to use for aligning product
  42. Jamieson Software toolbar
  43. Set Knife Origin
  44. Either of the following:
  45. move the laser head to the corner called out in the settings
  46. select a new knife origin, save the file, and download the new file to the machine.
  47. Check outside extents of product cut
  48. <TEST>
  49. Red dot moves to trace outside extents of intended cuts
  50. If any product edge is inside this traced box, the product may not be aligned with the laser cutting action
  51. Begin laser cutting action
  52. ShutBay Door
  53. Laser will not start with main bay door open
  54. <Start / Pause> “cutting of product starts”

3.Alternate Control Functions

  1. To “Pause and Restart” laser cutting action, use ONLY <Start / Pause> button
  2. Using any other method can cause timing belts to slip and lose counts
  3. Laser will no longer be aligned and the product cut must be aborted
  4. This is especially important if a Jig is used to align new product pieces for mass production
  5. To “ABORT” laser cutting action, use ONLY <Start / Pause> <STOP> sequence
  6. Using any other method can cause timing belts to slip and lose counts
  7. Laser will no longer be aligned and the product cut must be aborted
  8. This is especially important if a Jig is used to align new product pieces for mass production

4. Post Lab Assignments

Research one configuration parameter set that was not explained clearly and document the related relationships in the Appendix of this Exercise.

5. Appendix

Machine Control Panel

Menusub-MenuFunctionValue

Relationships

Jamieson CAD Software

Menusub-MenuFunctionValue

Relationships

AutoCAD

Menusub-MenuFunctionValue

Relationships