Mitsubishi Electric Releases 'CV Series' of 3D CO2 Laser Processing Systems for Cutting CFRP

Posted  by GoPhotonics

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Mitsubishi Electric Corporation announced the launch of two new CV Series models of 3D CO2 laser processing systems for cutting carbon fiber reinforced plastics (CFRP), which are lightweight, high-strength materials used in automobiles. The new models are equipped with CO2 laser oscillators that integrate the oscillator and amplifier into the same enclosure - a world-first based on the company's research as of October 14, 2021 - and together with the unique processing head of the CV Series, it helps achieve high-speed and precision processing. This will enable the mass production of CFRP products, so far unavailable using previous processing methods.

In recent years, there have been increased calls in the automobile industry for reductions in CO2 emissions, improved fuel efficiency, and more lightweight materials enabling greater cruising ranges. This is driving the increasing demand for CFRP, which is relatively new material. On the other hand, CFRP processing using existing technology has had issues such as high operating costs, low productivity, and issues with waste treatment. A new processing method was required.

Mitsubishi Electric's CV Series will overcome these challenges by achieving high productivity and processing quality far superior to existing processing methods helping to facilitate the mass production of CFRP products at a level that was hitherto unachievable. In addition, the new series will help to reduce the environmental burden by such means as a reduction in waste, thereby contributing to the realization of a sustainable society.

The new models will be exhibited at MECT 2021 (Mechatronics Technology Japan 2021) at Port Messe Nagoya, Nagoya International Exhibition Hall from October 20 to 23.

Overview of Release

Product name

Model name

Oscillator power

Release Date

Target Unit Sales

'CV Series' 3D CO2 laser processing systems for CFRP

ML1515CV-12XM

 

1.2kW

 

Oct. 18

100 machines (annually)

ML3122CV-12XM


Product Features

Unique 3-axis orthogonal type CO2 laser oscillator achieves exceptional CFRP processing speeds

For laser cutting of CFRP, a material generated from carbon fiber and resin, the fiber laser widely used for cutting sheet metal is not suitable as the beam absorption rate is extremely low for the resin and so the resin needs to be melted by thermal conduction from the carbon fiber. In addition, although CO2 lasers have a high laser energy absorption rate for both carbon fiber and resin, the conventional sheet metal cutting CO2 lasers do not have a steep pulse waveform making them unsuitable for cutting CFRP due to the high heat input into the resin.

Mitsubishi Electric has developed a CO2 laser oscillator for cutting CFRP by achieving both a steep pulse waveform and high output power. This Integrated-MOPA system 3-axis orthogonal-type CO2 laser oscillator enables the integration of the oscillator and amplifier into the same enclosure; it converts the beam oscillated at low power into a steep pulse waveform suited for cutting CFRP, and puts the beam into the discharge space again, amplifying the output. It is then possible to emit a laser beam suitable for CFRP processing by a simple configuration (patent pending).

Combining steep pulse waveforms and the high beam power required for CFRP cutting achieves exceptional, class-leading, processing speeds, about six times faster than existing processing methods such as cutting and waterjet, thereby helping to improve productivity.

Unique single-pass processing head achieves superior processing and helps protect the environment

The side gas nozzle on the processing head enables hot material vapor and dust generated during cutting to be removed until the very end of the cut material while still managing the thermal effects on the material, to achieve a superior processing quality unachievable using previous processing methods (patent pending). Also, as laser processing is non-contact, there are few consumables and no waste (e.g., waste liquid) is produced, which helps to reduce operating costs. This processing technology contributes to the realization of a sustainable society and the achievement of applicable UN Sustainable Development Goals.


The installation of "path edit function" and utilization of IoT improve work efficiency and ease of maintenance

Conventionally, the revision of processing paths needs to be edited with CAM (computer-aided manufacturing) software. However, the path can be corrected in the field by installing path edit CAM software in the controller, which improves operators' work efficiency.

Mitsubishi Electric's remote service deploying IoT, "iQ Care Remote4U", allows the operational status of laser processing machines to be checked in real-time. This remote service also helps to improve production processes and reduce operating costs by using IoT to collect and analyze processing performance, setup time, and electricity and gas consumption.

Moreover, it is possible to perform remote diagnosis of customers' laser processing machines directly from terminals installed in Mitsubishi Electric's service center. Even if a processing machine fails, a prompt response is guaranteed by means of remote operation. Preventive maintenance information, software version updates, and the processing of condition changes are also provided.