High Power Density and Reliability in Precision Laser Systems

IPG Photonics is the world leader in high-power fiber lasers and amplifiers, manufacturing precision laser workstations used for welding, cutting, and drilling applications. These systems, including the SYS-2500, SYS-3000, SYS-3000EV, and DLR Heating Cell, require precise motion control to manipulate laser heads, workpieces, and access doors with exceptional accuracy and speed.

For Sean LeBlanc, an Electrical Engineer at IPG Photonics, selecting the right motion control components involved balancing physical size constraints with high-performance requirements. The machines often operate in tight spaces but still require "aggressive speeds," moving up to 1 meter/second.

One of the primary challenges in designing compact laser workstations is finding motors that fit within the mechanical envelope without sacrificing power. Sean found that Teknic servo motors and drives offered a significant advantage in torque density.

When comparing Teknic servo motors to alternative options, Sean noted that the physical size was much more manageable while still delivering the necessary output.

This high power density allowed IPG to maintain a smaller machine footprint while achieving the rapid acceleration and velocity required for their laser processing cycles.

Beyond raw performance, ease of integration and long-term reliability were critical factors. IPG utilizes both ClearPath integrated servos and Hudson brushless servo motors.

Sean highlights that the use of industry-standard connectivity on both Teknic product lines streamlined the build process. "The M12 connectors are great because they're easy to find and industry standard," notes Sean.

Once deployed, the servo motors have proven exceptionally durable in the field. Despite the demanding nature of industrial laser processing, the failure rate has been virtually non-existent.

As IPG Photonics continues to evolve its machine designs, maintaining backward compatibility helps streamline service and upgrades. Teknic’s design philosophy ensures that newer generations of motors remain mechanically compatible with previous iterations.

"For replacements, you've got a clear path [no pun intended] to upgrade to the latest and greatest," says Sean. "Everything's compatible. It just bolts right in."

Looking ahead, Sean is also exploring Teknic’s EtherNet/IP and EtherCAT-enabled ClearPath models, ClearPath-IP and ClearPath-EC respectively, to further simplify programming and integration, particularly for machines utilizing Allen Bradley PLCs.