Laser cutting involves a huge amount of energy, and therefore possessing a proper air compressor system is crucial. The air compressor supplies compressed air to the laser cutter as well as other pneumatic accessories required in the process. Following the operating and maintenance procedures will help to increase the efficiency of the air compressor and decrease issues such as low pressure, high moisture, and wear and tear of other equipment. Choosing a reliable air compressor manufacturer ensures consistent performance, energy efficiency, and longevity, which are vital for demanding applications like laser cutting.
Proper Sizing
While choosing a laser air compressor one needs to differentiate between the adequate capacity also known as CFM rating for your particular equipment. Undersizing results in the compressor being unable to meet the required demand. Oversizing results in wastage of energy particularly when the equipment is working below its maximum capacity. Take into account not only the needs of the laser cutter but also any other air-powered tools that will be used and leave room for growth. Rotary screw compressors are ideal to have greater CFM laser cutting requirements because of their efficiency.
Location
Also, location of the air compressor and intake piping should be done in areas which have no dust or dirt so that the system will not be contaminated. It is important to ensure that there is proper air circulation around the compressor more so to avoid its over heating. Extreme temperatures either high or low are unhealthy to the life of the compressor and its efficiency. Always, design as close as possible to the points of use in order to minimize piping pressure drops.
Filtration
To filter out solid particulates and droplets of moisture or oil, you have to install high quality air filters. Dust particles tend to cause wear on the valves and seals. Condensation results in corrosion and formation of ice. It is also recommended to check and replace filters more often to avoid blockage. If lubricated rotary compressors are being used upstream, specific oil-removing filters should be applied. To promote the life expectancy of a laser cutter, it is crucial to keep the air around the device clean and dry.
Piping
Employ straight steel pipes instead of flexible hoses that result in high pressure drop across them. Make sure all the joints have a tight thread connection and then apply the right sealant at the points of the joint. Also, do not use too many elbowings and long runs as they cut delivered air pressure. Ensure that there are drains where water is likely to collect by ensuring there is a low point for water to drain. Applying heat trace, insulation, and sloped piping in the unheated space where freezing temperature is a possibility.
Receiver Tanks
In a way, when we use industrial screw air compressors for laser cutting, the receiver tanks aid in maintaining a constant air supply since it contains a supply of compressed air should there be an increase in demand. They also enable moisture to separate prior to entry into the distribution system. The general guideline is to select the receiver tank capacity to be 5 gallons per CFM of the compressor rating. Charge the tank pressure appropriately to attain optimal performance according to the manufacturer’s instructions.
Water Management
Compressed air systems should not be contaminated with moisture. Centrifugal compressors need after coolers while rotary screw compressors need air dryers to further remove moisture from the air after compression. The different types of dryers that are available are those which may be effective to a certain level and at a certain cost. It is usually adequate to employ a refrigerator dryer for most laser cutting uses, depending on the materials used. After the post dryer, there is a requirement to separate liquid condensate from the airstream. To ensure that this moisture is expelled before it finds its way back to the piping system, install drains, traps, and auto drain valves.
Bleed Valves & Dew Point Monitoring
However, it is also important to note that small amounts of moisture may still persist even after drying has been done. To avoid this build up, the bleed valves should be fitted in a way that allows a small amount of compressed air to escape periodically. The second option is to use dew point monitors that measure the moisture content and trigger the drains. This is more efficient than constant bleeding which would require more energy. To achieve the highest level of air dryness, desiccant dryers can be used although they are relatively expensive in terms of capital and regeneration costs.
Correct Control and Load/Unload Configuration
Categorized on pressure settings, stage compressors modulate the air delivery according to the demand. This is the pressure level at which more compressors are activated. Adjusted significantly high enough to avoid short cycling but not very high which is wasteful of energy. Load/unload controllers shut off the compressors when the pressure is high, so that they can operate at their full capacity if necessary.
Monitoring & Preventative Maintenance
Check air pressure in an air compressor for laser cutter regularly at the outlet side of the filters/dryers to observe constant decline suggestive of contamination or moisture content. If the pressure drop is more than 10 psi, the filters should be changed right away. Track compressor run hours and total system cycles so that you can perform preventive maintenance based on the recommendations of the manufacturers. This makes it possible to prevent early faults or even situations where the performance level drops.
Common preventative maintenance activities include:
- Changing of inlet air filter elements
- Compressor oil & filter replacement
- Testing/replacing air dryers
- Deep cleaning intercooler and aftercooler heat exchangers
- This involves inspecting belts/couplings to ensure they are in good condition and if not put in the correct position.
- Checking safety relief valves
- Ensuring all the joints, valves, and lines are free from loss of air.
Purchasing superior compressed air components and adhering to the best practices will help achieve the highest level of compressed air utilization at the lowest cost. This continues laser cutting production all day and night.Hopefully, you’ll get your very own quality screw air compressor.
