Coaxial rotation multi-light-spot hybrid scanning device and method
Technical Field
The invention relates to the field of three-dimensional printing, in particular to a coaxial rotary multi-light-spot hybrid scanning device and method.
Background
As a high-speed optical component, the multi-surface mirror scanning device has the advantages of high scanning speed, stable operation and small heat generation, and is used in the fields of medical imaging, material processing, laser printing plate making and the like. The optical scanning angle and scanning speed of the polygon mirror scanning device depend on the number of reflecting surfaces and the working rotation speed of the motor. The more reflecting surfaces, the smaller the optical scanning angle, the higher the motor rotation speed, and the more scanning times per second. Typical scanning speeds of the conventional polygon mirror scanning device are different from hundreds of lines to thousands of lines per second, and the moving speed of a dynamic light spot of a scanning line can be up to more than 1000 meters per second, which means that the detention time of the dynamic light spot on a single-point pixel of an imaging surface is extremely short, so that various application limitations are brought to the polygon mirror scanning device, and the polygon mirror scanning device mainly comprises: first, the laser must have high-speed dimming capability to achieve single-pixel serial output based planar scanning imaging; second, the laser must have sufficient optical power to apply enough energy to the imaging plane single point pixel within a very narrow time window; third, the imaging surface photosensitive medium must have sufficient sensitivity and response speed to ensure adequate photosensitive response. The above factors have long restricted the applicability of polygon scanning devices.
In recent years, with the rapid development of laser processing technology, thermal effects generated by irradiation of high polymers and metal materials with radio frequency and infrared lasers and photo-curing reactions excited by irradiation of photosensitive resin materials with ultraviolet lasers are gradually used in various types of three-dimensional printers, including laser selective melting (SLM), laser selective sintering (SLS), stereolithography (SLA) and other types. The laser scanning device has the following functions in the three-dimensional printer: laser energy is selectively applied to the object material interface according to a slice pattern of the three-dimensional digital model to facilitate thermal or catalytic consolidation of the illuminated region. The most common laser scanning device is a galvanometer type scanning galvanometer, and the motor rotor of the galvanometer type scanning galvanometer can be a low-inertia air coil with positioning speed which can be tens of times that of a common servo motor; however, when complex patterns, especially lattice structures which are widely applied in the field of three-dimensional printing, are output, the high discreteness and a large number of detail features of slice patterns lead to a scanning path containing a high proportion of vector turning and idle stroke jumping, and seriously affect the scanning imaging speed. Recently, a case of reporting that the polygon mirror scanning device is used for SLA light curing three-dimensional printing is disclosed, but the limitation of the prior art is inherited, and particularly, the laser energy requirement of the three-dimensional printing on single-point pixels is far higher than that of the traditional application scene. This directly results in the three-dimensional printer having to reduce the motor operating speed of the polygon scanning device, thereby diminishing its high speed advantage over other laser scanning devices. At present, in the field of three-dimensional printing, aiming at the urgent need of further improving the performance of a laser scanning device, a laser scanning method which has the advantages of simple structure, high imaging speed and large single-point pixel energy and does not lose imaging performance when outputting complex patterns is lacking.
Disclosure of Invention
The invention aims to solve the defects of the prior art, and provides a coaxial rotary multi-spot hybrid scanning device and a coaxial rotary multi-spot hybrid scanning method which have the advantages of simple structure, high imaging speed and high single-point pixel energy, and do not lose imaging performance when outputting complex patterns.
The invention solves the technical problems by adopting the technical scheme that: the coaxial rotary multi-spot hybrid scanning device comprises a linear module, a rigid support, a motor, a reflecting mirror group, a laser group, an imaging surface and a scanning controller. The linear module is connected with the rigid support and can drive the rigid support to translate and position; the motor and the laser set are fixed on the rigid support, and the reflecting mirror set is connected on the output shaft of the motor in series; the positive sections of all the reflectors of the reflector group are regular polygons with the same shape, the motor can drive the reflectors connected in series to synchronously rotate, and the rotation axis is parallel to the translation direction of the linear module; the number of lasers of the laser group is n and the number of reflectors of the reflector group are paired one by one, and laser beams emitted by the lasers are deflected and reflected by the reflecting surfaces of the paired reflectors to generate light spot scanning lines on the imaging surface; after the parallel laser beams emitted by the laser group are deflected and reflected by the reflecting mirror group, n light spot scanning lines are generated on an imaging surface, and the distance between the light spot scanning lines is the same as the distance between the lasers on the rigid support; when the linear module drives the rigid support to continuously move, the n facula scanning lines synchronously move along with the rigid support, so that the n facula scanning lines scan on an imaging surface line by line at the same time until a plane image covering an imaging area of the imaging surface is formed; the scanning controller is electrically connected with the linear module, the motor and the laser set.
The motor is internally provided with a rotary encoder, and the rotary encoder outputs m increment pulses and 1 synchronization pulse for every 1 turn of the motor, and is used for controlling a laser group to realize pixel-by-pixel optical power control of a light spot scanning line, and the method comprises the following specific steps of; the scan controller decodes and counts the increment pulse and the synchronization pulse first: adding 1 to each increment pulse counting register value, resetting the counter to a zero-resetting counter when the counting register value is increased to m, and setting the counting register as an initial value when receiving the synchronous pulse; when the value of the counting register is {0, m/p,2m/p … (p-1) ×m/p }, the scanning controller generates row synchronizing signals of the 1 st to p th reflecting surfaces, and the scanning controller adjusts the initial value of the counting register between 1 and m/p so that the row synchronizing signals coincide with scanning windows of the reflecting surfaces; each spot scanning line has k pixels, and the scanning controller performs k equal division operation on the spot scanning lines to obtain a clock interval table of 1-k pixels; the scanning controller queries the interval position of the system clock count value in the clock interval table in real time in each line synchronizing signal period to obtain the pixel number of the dynamic light spot in the light spot scanning line; the scanning controller positions the pixel gray values which are required to be projected by each laser in the row pixel data buffer areas of the 1 st to n th lasers according to the pixel numbers, and then converts the pixel gray values into optical power control signals and outputs the optical power control signals to each laser.
When SLA planar scanning imaging is carried out, the laser groups and the reflector groups are arranged at equal intervals along the moving direction of the linear module; the foremost laser-reflector pair is made to be the nth group, the rearmost group is made to be the 1 st group, and the imaging area shares k rows of pixels, so that the ith (i is more than or equal to 1) group of laser-reflectors is responsible for the ((i-1) k/n+1) th row to the ik/n th row, and the progressive scanning range of each group of laser-reflectors is k/n rows; the linear module drives the 1 st group of laser-reflecting mirrors to move forward from the 1 st row and scan to the k/n row line by line, and the 2 nd group of laser-reflecting mirrors also scan to the 2k/n row from the k/n+1 row; by analogy, the nth group of laser-reflecting mirrors are scanned from the (n-1) th k/n+1 th row to the kth row, and the nth group of laser-reflecting mirrors are divided into work to finish the planar scanning imaging of the whole SLA imaging area; during the movement of the linear module, the scanning controller receives a linear module position signal, calculates the spot scanning line position of the 1 st group of lasers-reflectors in real time according to the pixel line spacing of the imaging surface, further superimposes an offset value k/n to obtain the scanning line position of the 2 nd group of lasers-reflectors, and the like until the nth group of lasers-reflectors; and the scanning controller respectively refreshes the pixel data of the corresponding rows of the SLA plane image to the row pixel data buffer areas of the 1 st to n th lasers according to the scanning line positions of the 1 st to n th lasers-reflecting mirrors.
When SLS/SLM plane scanning imaging is carried out, the laser group and the reflecting mirror group are closely arranged along the moving direction of the linear module; the foremost laser-reflector pairing is made to be the nth group and the rearmost group is made to be the 1 st group, then the 2n/3+1 th group to the nth group are preheating areas, the nth/3+1 th group to the 2n/3 th group are forming areas, and the 1 st group to the nth/3 th group are heat treatment areas; the SLS/SLM plane imaging area is made to share k rows of pixels, the linear module drives the nth group of laser-reflecting mirrors to scan forwards from the 1 st row until the 1 st group of laser-reflecting mirrors at the rearmost reaches the kth row, and the plane scanning imaging is completed; during the movement of the linear module, the laser-reflecting mirror in the preheating zone pre-heats the powder, then the laser-reflecting mirror in the forming zone sinters/melts the powder, and finally the laser-reflecting mirror in the heat treatment zone re-heats the formed body so as to improve the mechanical property; the scanning controller receives the linear module position signal, calculates the scanning line position of the nth group of lasers-reflecting mirrors in real time according to the pixel line spacing of the imaging surface, and further superimposes an offset value-q/(n-1) to obtain the scanning line position of the nth-1 group of lasers-reflecting mirrors, and the like until the 1 st group of lasers-reflecting mirrors, wherein q is a line offset value corresponding to the spacing between the 1 st group of lasers and the nth group of lasers; and the scanning controller refreshes the pixel data of the corresponding rows of the SLS/SLM planar image to the row pixel data buffer areas of the 1 st to n th lasers respectively according to the scanning line positions of the 1 st to n th lasers-reflecting mirrors, and when the scanning line positions are positioned outside the planar imaging area, the scanning controller empties the row pixel data buffer areas of the corresponding lasers.
According to the invention, the motor output shaft is connected with n polygon mirrors with the same cross section in series, each mirror is provided with a uniquely matched laser, when the motor drives a mirror group formed by the n mirrors to rotate at the same time, each mirror can generate 1 facula scanning line on an imaging surface through the matched laser, namely, n dynamic facula are scanned and imaged on the imaging surface at any moment; the scanning controller generates row synchronous signals of p reflecting surfaces based on pulse signals of an encoder arranged in a motor, equally divides light spot scanning lines in each row synchronous signal period to obtain a clock interval table of k pixels, and further obtains pixel numbers of dynamic light spots in the light spot scanning lines by inquiring interval positions of clock count values of a system in the clock interval table in real time; the n lasers of the invention use the same pixel number to locate the pixel gray value to be projected from the respective row pixel data buffers.
According to the coaxial rotating multi-light-spot hybrid scanning method, an SLA imaging area can be equally divided into a plurality of sections along the moving direction of the linear module, the linear module only needs to move 1 section of area, and the laser group and the reflecting mirror group can finish progressive scanning imaging of all imaging areas; when SLA planar imaging is carried out, the scanning imaging speed is in direct proportion to the number of elements of the laser group/reflector group, and the larger the number of the used lasers/reflectors is, the faster the scanning imaging speed is; when the linear module moves forward, powder materials at any row position of the SLS/SLM plane imaging area are sequentially irradiated by light spot scanning lines of the preheating area, the forming area and the heat treatment area, so that the optical power of the n-th group to the 1-th group of lasers can be freely set along a time axis according to a required preheating-forming-heat treatment power curve to match the forming process requirements of different powder materials.
The coaxial rotary multi-light spot hybrid scanning device and the method thereof have the advantages of compact structure, simple driving, low cost and high plane scanning imaging efficiency, and can be popularized and applied in various laser scanning three-dimensional printers.
Drawings
FIG. 1 is a schematic diagram of the overall structure of an embodiment of the present invention;
FIG. 2 is a control signal connection diagram of an embodiment of the present invention;
FIG. 3 is a schematic view of SLA planar scanning imaging according to an embodiment of the present invention;
FIG. 4 is a schematic illustration of SLS/SLM planar scanning imaging in accordance with an embodiment of the present invention;
FIG. 5 is a diagram of a laser group brightness control logic according to an embodiment of the present invention;
FIG. 6 is a schematic view of the rigid support and its upper components;
reference numerals illustrate: the laser device comprises a linear module 1, a rigid support 2, a motor 3, a laser group 4, a laser I41, a laser beam I410, a dynamic light spot I411, a light spot scanning line I412, a laser II 42, a laser beam II 420, a dynamic light spot II 421, a light spot scanning line II 422, a laser III 43, a laser beam III 430, a dynamic light spot III 431, a light spot scanning line III 432, a mirror group 5, a mirror I51, a mirror II 52, a mirror III 53, an imaging surface 6, an imaging area 61, an imaging section I611, an imaging section II 612, an imaging section III 613, a scanning cut-in section 62, a scanning exit section 63, a scanning controller 100, a decoder module I101, a decoder module II 102, a line scanning control module 103, a line scanning control module 104, a line data selection module 105, a plane image storage area 106 and a laser control module 107.
Detailed Description
The invention is further described below with reference to the accompanying drawings:
as shown in fig. 1 and 6, a coaxial rotary multi-spot hybrid scanning device is provided, a rigid support 2 is arranged on a moving platform of a linear module 1, a motor 3 and a laser set 4 are arranged on the rigid support 2 (in this embodiment, the laser set 4 comprises three lasers, namely a first laser 41, a second laser 42 and a third laser 43), an output shaft of the motor 3 is connected with a mirror set 5 (the mirror set 5 comprises a first mirror 51, a second mirror 52 and a third mirror 53 which are connected in series), and the mirrors 51, 52 and 53 have the same regular polygon cross section, and each side of the regular polygon corresponds to 1 reflecting surface; when the motor 3 drives the reflectors 51, 52 and 53 to rotate together; after being deflected and reflected by the reflecting surfaces of the reflecting mirror I51, the laser beam I410 emitted by the laser I41 forms a dynamic light spot I411 and a light spot scanning line I412 on the imaging surface 6 above the linear module 1; by analogy, a second laser beam 420 emitted by a second laser 42 is deflected and reflected by a second reflecting mirror 52 to generate a second dynamic light spot 421 and a second light spot scanning line 422 on the imaging surface 6, and a third laser beam 430 emitted by a third laser 43 is deflected and reflected by a third reflecting mirror 53 to generate a third dynamic light spot 431 and a third light spot scanning line 432 on the imaging surface 6; the linear module 1 can drive the rigid support 2, so as to drive the motor 3, the laser set 4 and the reflector set 5 to perform reciprocating scanning motion, and the motion direction is perpendicular to the light spot scanning lines 412, 422 and 432.
As shown in fig. 2, a scanning controller 100 is connected with a linear module 1, the scanning controller 100 is connected with a motor 3, and the scanning controller 100 is connected with a laser group 4; the scanning controller 100 sends out an electric signal to the linear module 1 to control the linear module 1 to drive the motor 3, the laser set 4 and the reflecting mirror set 5 to translate, and then the imaging surface 6 is subjected to plane scanning imaging through the light spot scanning lines generated by the laser set 4 and the reflecting mirror set 5; the scanning controller 100 sends out an electric signal to the motor 3 to control the motor 3 to drive the reflector group 5 to continuously rotate, and further drive the laser beams 410, 420 and 430 to deflect and reflect, so that the dynamic light spots 411, 421 and 431 generate light spot scanning lines 412, 422 and 432 on the imaging surface 6; the scan controller 100 sends an electrical signal to the laser set 4 to adjust the optical power of the lasers 41, 42, 43 in real time according to the pixel numbers of the dynamic light spots 411, 421, 431 and the line pixel buffer data, so as to realize the pixel-by-pixel brightness control of the light spot scan lines 412, 422, 432.
As shown in fig. 5, the scan controller 100 includes a first decoder module 101, a second decoder module 102, a row scan control module 103, a column scan control module 104, a row data selection module 105, a planar image memory area 106, and a laser control module 107; the motor 3 outputs a rotation pulse signal to the first decoder module 101, the first decoder module 101 outputs an angular position signal to the line scanning control module 103, and the line scanning control module 103 outputs pixel numbers of the dynamic light spots 411, 421 and 431 to the laser control module 107; the linear module 1 outputs a displacement pulse signal to the decoder module two 102, the decoder module two 102 outputs a position signal of the linear module 1 to the column scanning control module 104, and the column scanning control module 104 outputs the positions of the light spot scanning lines 412, 422 and 432 to the line data selecting module 105; the planar image memory area 106 outputs image data to be scanned to the line data selecting module 105, and the line data selecting module 105 outputs line pixel data to the line pixel data buffer of the laser control module 107; the laser control module 107 converts the pixel gray values of the line data buffer into optical power control signals according to the dynamic spot pixel numbers, and outputs the optical power control signals to the lasers 41, 42 and 43 respectively.
As shown in fig. 3, the sla imaging area 61 is trisected into an imaging section 611, an imaging section 612 and an imaging section 613 along the moving direction of the linear module 1; at the beginning of planar scanning imaging, spot scan lines 412, 422, 432 are located at the beginning row positions of imaging segments 611, 612, 613, respectively; when the linear module 1 drives the rigid support 2 and further drives the motor 3, the laser set 4 and the reflector set 5 to translate forwards, the light spot scanning lines 412, 422 and 432 also move forwards in the imaging sections 611, 612 and 613 respectively; the scanning controller 100 refreshes the line pixel data buffer areas of the lasers 41, 42 and 43 in real time according to the line positions of the light spot scanning lines 412, 422 and 432, so that the brightness distribution of the light spot scanning lines 412, 422 and 432 is consistent with the pixel gray distribution of the corresponding line of the SLA plane image; the spot scan lines 412, 422, 432 reach the end rows of the imaging segments 611, 612, and 613, respectively, and the scanned areas 614, 615, 616 of the spot scan lines 412, 422, 432 also extend forward to the end rows of the imaging segments 611, 612, and 613, respectively, such that the scanned areas 614, 615, 616 cover the entire SLA imaging area 61 end-to-end;
referring to fig. 4, referring to the moving direction of the linear module 1, the rear side of the SLS/SLM imaging region 61 is a scanning cut-in section 62, and the front side is a scanning exit section 63; at the beginning of planar scanning imaging, spot scanning line 432 is located at the beginning line position of imaging region 61, and spot scanning lines 422, 412 are located at scan cut-in section 62; when the linear module 1 moves forward, the light spot scanning lines 412, 422 and 432 move forward, when the light spot scanning line 412 reaches the imaging area 61 and stops, the light spot scanning lines 422 and 432 enter the scanning exit section 63, and SLS/SLM plane scanning imaging is completed; in the moving process of the linear module, the scanning controller 100 refreshes the line pixel data buffer areas of the lasers 41, 42 and 43 in real time according to the line positions of the light spot scanning lines 412, 422 and 432, so that the brightness distribution of the light spot scanning lines 412, 422 and 432 is consistent with the pixel gray scale distribution of the corresponding line of the SLS/SLM planar image, and when the light spot scanning lines 412, 422 and 432 are positioned in the scanning cut-in section 62 and the scanning exit section 63, the scanning controller empties the line pixel data buffer areas of the corresponding lasers; after the planar scanning imaging is completed, any row position of the imaging region 61 has been scanned sequentially by the spot scanning lines 412, 422, 432.
The laser set and the reflector set of the invention can adopt more elements besides 3 elements in the embodiment, and the corresponding scanning performance is higher; in addition to the serial connection of the 3 reflectors in the embodiment, a single long prism-shaped reflector can also be adopted, and the corresponding length of the long prism-shaped reflecting surface should cover the distribution area of all laser beams of the laser set; the coaxial rotation multi-light spot hybrid scanning method can also be used for multi-layer vertical splicing three-dimensional printing, namely, each light spot scanning line is responsible for 1-layer plane scanning imaging, and multi-layer dislocation and synchronous imaging.
Compared with the prior art that a plurality of traditional multi-surface reflecting mirror scanning devices are deployed at the same time, the coaxial rotating reflecting mirror scanning device has more compact structure, simpler control, better synchronism and more flexible scanning mode, can work in mixed scanning modes such as multi-scanning line space splicing, multi-scanning line time domain splicing and the like, and can meet the imaging requirement of a three-dimensional printer on the laser scanning device more widely.
In addition to the embodiments described above, other embodiments of the invention are possible. All technical schemes formed by equivalent substitution or equivalent transformation fall within the protection scope of the invention.