Yesterday I was working on a tree of life design on the CO2 #laser. It's a hand-drawn line-drawing with lots of intricate detail that we're planning to make a divination board of.
This is a relatively large board, so the #engraving takes a while, so I tend to let it do it's thing while I'm in the room working on other stuff.
Then, I happen to look at it and notice it's all screwy - the lines are showing up double. Oh Nooooo...
The rest of my day was basically consumed with debugging the laser.
Ghosting or double-lines usually mean something screwy in the optical path, specifically in terms of the verticality of the laser. If the beam isn't hiting the focus lens in the center, you can end up with this problem, or if the beam is hitting the edge of the nozzle and is being reflected, you can also have this issue.
I did the 'ol mirror alignment test with the tape... nope,... everything looks dead center.
I did notice some debris in the nozzle so i cleaned that out thoroughly, it's never been cleaner - issue still persists.
Then I grabbed a mirror and a light, and pointed the light at the hole where the beam normally enters the head, and angled the mirror below the nozzle such that I could see the entire optical path - looks completely perfectly clear ... well darn...
I had to somehow rule out optical versus mechanical issues, so what I came up with was #laserengraving two crosses, one just made up of single lines, the other of filled lines. If both have double lines, the issue is likely optical. If only the filled cross has double lines, the issue is just mechanical.
Sure enough, the thin line cross came out just fine, so the issue isn't optical.
This also revealed clearly the problem only happens on the X axis.
So I proceed to clean the heck out of the x axis belt, it was fine... didn't help... tension was fine too..
Then I looked for 'wiggle' in the laser nozzle... now.. it always had some wiggle in it, so I didn't think too much of it, but it seemed worse somehow... wondered if that could be it...
I had to track down where the wiggle even came from. It's not the laser head itself, just the nozzle part.
After lots of back-breaking awkward bending and looking around with lights and mirrors, I discovered that this #monport onyx R laser has two little screws hidden BEHIND where the belt attaches, that fix the laser nozzle assembly to the rest of the larger laser head.
They are impossible to tighten without removing the belt first... ughhh....
Lots of fiddly screwing around later, I was able to tighten these little screws, and sure enough, no more wobble. It's more solid now than it ever was even since first we got the laser.
And sure enough, that fixed the problem.
Not optics, not verticality,... just two little stupid screws.
I'm guessing they were never fully tightened when it left the factory (hence the, it always had some wobble to it...) and just became increasingly loose until loose enough to become a problem. When I initially found the screws, one of them was just short of completely falling out. Go figure.