This level of fine precision requires not only highperformance laser systems but also motion control solutions that can eliminate mechanical imperfections such as backlash in ballscrew stages. As Waleed Hafez, Senior Development Engineer at Watt Laser, notes:
“ With ballscrew stages, we do get some backlash. With Renishaw encoders, we’ re able to measure and correct for the backlash in real time.”
Another challenge was scalability. Watt Laser needed to streamline its production processes to meet increasing demand without compromising quality. Installation speed and reliability became critical. Fraser Hemming, Senior Product Engineer at Watt Laser, highlights this:
“ We needed to get a high-accuracy quality machine to market as quickly as possible.”
Additionally, Watt Laser’ s inspection systems, such as the QC100, required encoder solutions capable of measuring micron-level features.
Solution
Renishaw ATOM encoders
ATOM encoders provide position measurement at fine resolutions, down to 0.1 micron, for ultra-precise motion control. The compact readhead design allows easy integration into custom laser systems and an integrated set-up LED simplifies installation. ATOM readheads feature filtering optics which provide superior signal stability and reliability, essential for maintaining accuracy during multi-pass laser processing.
Hemming explains,“ The resolution is appropriate for all our applications. We’ ve managed to increase our throughput of machines by 30 % since we started installing the ATOM systems.” Hafez adds,“ The ATOM encoder enables us to have fine control over the motion profiles. Our laser path is incredibly smooth and precise, which enables us to have the best products.”
Renishaw ADTpro-100 Advanced Diagnostic Tool
The ADTpro-100 tool offers various functions to enhance encoder installation and maintenance. A colour touch screen provides plug-and-play functionality with no need for external software. Comprehensive real-time encoder data is immediately available, including encoder serial number, status, signal size, and signal Lissajous plot. The ADTpro-100 is a portable, handheld diagnostic tool ideal for both manufacturing and in-field optimisation or faultfinding.
Hafez describes it as“ a useful tool … it makes installation a lot quicker and easier.” He also notes a 30 % increase in installation throughput thanks to the ADTpro-100’ s streamlined set-up process.“ It’ s super easy to use,” Hafez says,“ and there’ s not much training required.”
Results
The collaboration between Watt Laser and Renishaw has delivered measurable and strategic benefits across multiple areas:
1. Enhanced precision and product quality
Renishaw encoders have enabled Watt Laser to achieve and maintain sub-micron accuracy across its systems. This precision is critical in sectors like electronics and semiconductor packaging, where even the smallest deviation can result in product failure. Hafez emphasises,“ We’ re able to create intricate features. Without the 0.1 micron resolution, we wouldn’ t be able to have that repeatability.”
2. Increased throughput and efficiency
The ease of installation and reliability of Renishaw encoders have led to a 30 % increase in machine build throughput, allowing Watt Laser to meet growing demand without sacrificing quality.
Fraser confirms,“ We can install the ATOM encoder quickly. It gives us more throughput for our machines.”
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