Retrofitting Amada CO2 Laser Machine to Fiber Laser

        Do you have a high energy consumption, low efficiency, and high maintenance cost Amada CO2 Laser? If your businesses rely on laser cutting technology, but older models may not meet the demands of your work needs. With high energy consumption, lower efficiency, and increased maintenance costs, it's time to consider an upgrade! This article will explore how to transform your Amada CO2 laser into a fiber laser system that offers improved performance, reduced costs, and simplified maintenance.

1 About Your Machine Amada CO2 Laser Machine

       Amada is a prominent player in the laser equipment industry, known for its innovative solutions and high-quality products. The company specializes in a range of laser technologies, including CO2 lasers, which have been widely used in various manufacturing applications. Amada's CO2 lasers are known for their robust build quality and reliability. They deliver excellent cutting performance for a range of materials. However, as technology advances, these machines can become less efficient compared to newer options.    

       Retrofitting Amada CO2 lasers to fiber lasers presents significant value. This transformation not only enhances energy efficiency and reduces maintenance costs but also improves cutting speed and precision. By upgrading to a fiber laser system, businesses can unlock the full potential of their existing equipment and  lower the cost of the opreration.

1.1 The main models of Amada laser we can retrofit and upgrade

We can modify any AMADA model that uses the FANUC control system, including the following models:

(1) LCG Series

• LCG: Currently produced CO2 laser cutting machine.
• LCG AJ: Fiber laser cutting model, introduced around 10 years ago.

(2) FO Series

• FO NT: An older model from 20 years ago.
• FO (with full enclosure): Equipped with AMADA's own AMNC human-machine interface software.
• FOMII NT: An upgraded model from 10-15 years ago.

(3) FO Second Generation

• Second-generation version of the FO series; specific model details not provided.

(4)Other Models

• LC C1: Combination punch-laser machine, introduced around 10 years ago with 3000W power.
• LC A: Laser-only cutting model.
• EML: Combination punch-laser model.
• FOL: High-speed laser cutting machine.
• LC F1: High-speed laser cutting machine.       

2 CO2 Laser Cutter VS Fiber Laser Cutter

2.1  Comparative Analysis

(1)CO2 laser cutter:

• CO2 laser cutting machines are energy-intensive. Their electro-optical efficiency is around 10%, significantly lower than the 30% or more offered by fiber lasers, leading to higher energy consumption for equivalent power.
• CO2 lasers require the use of laser gas, which adds to operating costs.
• Traditional CO2 lasers utilize mirror reflection, resulting in a more complex structure. This complexity translates into intricate and expensive maintenance.
• Traditional CO2 lasers is being phased out, the production of their core components is being suspended. This makes the cost of core components considerably high due to their decreasing availability.  

(2) Fiber laser cutter:

• 30% Equipment Efficiency Improvement: superior metal absorption rates increased energy density, and accelerated cutting efficiency, fiber laser cutting machines offer a highly efficient solution. 
• 50% Reduction in Operating:These machines significantly reduce operating costs, as well as repair maintenance and  spare parts expenses, making them a financially smart choice. 
• Simplified Laser Transmission:The replacement of specular reflection with flexible optical fiber streamlines  maintenance and minimizes the equipment's footprint, making fiber lasers simpler and more compact.

2.2 Energy Consumption Comparison

➢ Under the same power, fiber lasers consume at least half the energy, saving more with higher usage.

2.3 Maintenance Cost Comparison

➢ No need for laser gas generation with fiber lasers, saving nearly 2000 USD annually.

➢ Fiber lasers can use air cutting, saving nearly 2000 USD on nitrogen costs per year.

➢ After upgrading, lasers come with a new 5-year warranty for 6KW machines, for worry-free operation.

➢ Equipped with a customized cutting head for stable performance.

3 Why Retrofitting?

3.1 Significant Cost-Effectiveness

Purchasing a brand-new fiber laser cutter requires a huge investment. Choosing to upgrade and retrofit the existing Amada CO2 laser cutter is a more cost-effective option. During the upgrade and retrofit process, only key components such as the fiber laser generator, water chiller, laser cutting head, and control system need to be replaced or upgraded to achieve a significant improvement in equipment performance. The cost is only half or even lower than that of purchasing new equipment. At the same time, part of the structure and function of the original equipment can be retained, maximizing the utilization of resources.

3.2 High Familiarity of Operators

The operators in the enterprise are usually very familiar with the operation and maintenance processes of the existing CO2 laser cutter. Through the upgrade and retrofit, they can quickly adapt to the new fiber laser cutting technology on the basis of the familiar equipment, reducing training costs and time, improving production efficiency, and reducing the operational risks caused by equipment replacement.

3.3 Reducing Resource Waste

In today's era of increasing environmental awareness, reducing resource waste has become an important part of corporate social responsibility. Upgrading and retrofitting the existing CO2 laser cutter avoids a large amount of waste generated by the elimination of equipment, and also reduces the enterprise's demand for new equipment, thereby reducing the consumption of resources and the impact on the environment during the production of new equipment.

3.4 Extended Machine Life

       Upgrading a machine with new technology can also extend its useful life, providing further cost savings over the long term.

4 Solution Details

4.1The Retained Parts in the Retrofit

During the upgrade and retrofit process, we will retain the machine structure, drive system, operation mode, and CNC system of the original Amada CO2 laser cutter. The purpose of doing this is to ensure that the operators can quickly get started with the new equipment, reduce training costs and time, and also retain some of the advantages of the original equipment, such as a stable mechanical structure and a mature operation process.

4.2 The Replaced Parts in the Retrofit

• Fiber Laser Source
• Water Chiller
• Laser Cutting Head
• Consumable Parts
• Controller
• Structure Parts 

(1) Fiber Laser Generator: The fiber laser generator has the advantages of high electro-optical conversion efficiency, low energy consumption, and maintenance-free, and can save more than 50% energy and cost by using fiber laser generator instead of CO2 laser generator.

(2) Water Chiller: A water chiller of the Tongfei brand is selected, which is specially designed for fiber laser cutters. This water chiller can provide a stable low-temperature environment to ensure that the fiber laser generator is always in the best state during the working process, improving the reliability and service life of the equipment and reducing energy consumption.

(3) Laser Cutting Head: The fiber laser cutting head is customized. It has the characteristics of high precision, high speed, and high stability, and can achieve more precise cutting effects to meet the cutting needs of different materials and thicknesses.

(4) Control System: A special control system independently developed by the Sky Fire expert team is installed. This control system perfectly matches the fiber laser cutter and can achieve more accurate control of cutting parameters, improve the automation degree and operation convenience of the equipment, and also has the functions of fault diagnosis and early warning, facilitating the maintenance and management of the equipment.

4.3 The Performance Improvement after the Retrofit

(1) Significantly Enhanced Cutting Capacity: The cutting capacity of the upgraded fiber laser cutter has been qualitatively improved. Taking common metal materials as an example, a 3000W fiber laser cutter can cut 20mm thick mild steel, 12mm thick stainless steel, and 10mm thick aluminum alloy; with the increase of power, a 6000W fiber laser cutter can cut 25mm thick stainless steel and 25mm thick aluminum alloy, which can meet the needs of more complex cutting tasks.

(2) Significantly Reduced Energy Consumption: As mentioned above, the energy consumption of the fiber laser cutter is only about half that of the CO2 laser cutter. In actual production, this means that enterprises can save a large amount of electricity costs every year, reduce production costs, and improve the competitiveness of enterprises.

(3) Greatly Reduced Maintenance Costs: The maintenance-free characteristics and longer service life of the fiber laser cutter have significantly reduced the enterprise's investment in equipment maintenance. There is no need to frequently replace consumables such as laser gas and lenses, and the downtime caused by equipment failures is also reduced, improving production efficiency.

5 Value Proposition for Customers

5.1 High Economic Value

• Boosted electro-optical efficiency
• Maintenance-free operation
• Elimination of gas source
• No replacement of operating or control systems
• On-site, fast transformation
• Extended equipment operational lifespan
• Retained mechanical performance and precision

5.2 Low Maintenance Cost:

• Cutting capabilities by material and laser wattage

5.3 Fiber Laser Cutting Ability (for reference)

• Cutting capabilities by material and laser wattage

6 On-site Modification Plan

7  Configuration List

8 Collaboration Process

9 Q&A

1. What is the core difference between fiber laser cutting and CO2 laser cutting?

Answer: Fiber laser cutting is more efficient and consumes less energy. Unlike CO2 lasers, fiber lasers don't require laser gases, significantly reducing maintenance costs. Fiber lasers have an energy conversion efficiency of 30%, compared to 10-15% for CO2 lasers. Additionally, the maintenance of fiber laser cutting heads is simpler, and the cutting speed is faster.

2. Why should I upgrade my CO2 laser cutting machine to a fiber laser cutter instead of buying a new one?

Answer: Upgrading your existing CO2 laser cutter saves a substantial amount of money compared to purchasing new equipment. The upgraded machine enhances cutting efficiency, reduces operational and maintenance costs, and avoids retraining operators. You retain the excellent performance of your current machine and extend its lifespan, saving hundreds of thousands in investment.

3. What Amada models can be upgraded?

Answer: We currently retrofit  LCG Series,FO Series, FO Second Generation and other models(For specific information, please refer to section 1.1, The Main Models of Amada Lasers We Can Retrofit and Upgrade). These machines can be upgraded to fiber laser technology, improving cutting efficiency, extending equipment life, and reducing maintenance costs. The upgrade does not require significant modifications to the machine bed or CNC system, ensuring a quick, cost-effective, and efficient process.

4. How long does the upgrade take, and will production be affected?

Answer: Typically, upgrades are completed within 2-3 days and can be done over the weekend to minimize production interruptions. With proper preparation, the process is quick and has minimal impact on the production schedule.

5. Do operators need retraining after the upgrade?

Answer: No. We retain the original operating system and interface, so no additional operator training is required. The upgraded machine operates the same way it did before, ensuring a seamless transition.

6. What is the warranty period for the upgraded equipment? 

Answer: We offer a 2-year warranty for the fiber laser source and a 1-year warranty for other parts. The upgraded Amada machine can continue operating for at least 10 years, with long-term maintenance and technical support services available to ensure stable operation.

Further Reading:

• retrofit bystronic co2 laser into a fiber laser
• retrofit YAG laser into fiber laser
• from co2 to fiber:enhancing trumpf laser performance