CN114485482A - Calibration module of galvanometer scanning system - Google Patents
Calibration module of galvanometer scanning system Download PDFInfo
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- CN114485482A CN114485482A CN202210210768.6A CN202210210768A CN114485482A CN 114485482 A CN114485482 A CN 114485482A CN 202210210768 A CN202210210768 A CN 202210210768A CN 114485482 A CN114485482 A CN 114485482A
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- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2504—Calibration devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2518—Projection by scanning of the object
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- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B26/00—Optical devices or arrangements for the control of light using movable or deformable optical elements
- G02B26/08—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
- G02B26/10—Scanning systems
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/80—Analysis of captured images to determine intrinsic or extrinsic camera parameters, i.e. camera calibration
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30204—Marker
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses a calibration module of a galvanometer scanning system, which belongs to the technical field of 3D printing and comprises an image acquisition unit, a target plate, a coordinate correction unit and a galvanometer control unit, wherein a target point with a distance which does not accord with a preset error distance from the target point is firstly screened out as a point to be corrected, then laser is reflected to the target plate in a row-column scanning mode by taking the minimum step length of a stepping motor and the stepping motor as a unit, then a picture is obtained, a correction point is selected, and the technical problem of high-precision calibration of the galvanometer is solved. The program design is greatly simplified, and high-precision and quick correction can be realized.
Description
Technical Field
The invention belongs to the technical field of 3D printing, and particularly relates to a calibration module of a galvanometer scanning system.
Background
The laser system is a laser generating component in a 3D printer.
The galvanometer component is a common component in a 3D printer, generally comprises two reflecting lenses, one reflecting lens can rotate in the vertical direction, the other reflecting lens can rotate in the horizontal direction, and laser can be reflected to a target to be engraved through the angle matching of the two reflecting lenses.
The galvanometer assembly generally controls the rotation of the mirror plate through a stepping motor, the stepping motor for controlling the mirror plate to rotate in the vertical direction is a stepping motor in the vertical direction, and the stepping motor for controlling the mirror plate to rotate in the horizontal direction is a stepping motor in the horizontal direction.
The precision of the galvanometer component determines the processing precision of the 3D printer at present, and due to errors of a stepping motor and a mechanical structure, a laser irradiation point reflected by the galvanometer can deviate from a theoretical position to a certain extent, so that the galvanometer can be put into industrial use after being calibrated.
The traditional correction scheme is that a laser irradiation point is photographed, after the position of the irradiation point is identified, the rotation angle of the stepping motor is obtained through calculation.
Disclosure of Invention
The invention aims to provide a calibration module of a galvanometer scanning system, which solves the technical problem of high-precision calibration of the galvanometer.
In order to achieve the purpose, the invention adopts the following technical scheme: a calibration module of a galvanometer scanning system comprises a laser system, a galvanometer component, an image acquisition unit, a target plate, a coordinate correction unit and a galvanometer control unit, wherein the target plate comprises a substrate, a plurality of target points are coated on the substrate, laser light emitted by the laser system is reflected by the galvanometer component and then emitted to the target plate to obtain irradiation points of the laser, namely target points;
the galvanometer control unit comprises a control module, a first angle feedback module, a first encoder, a second angle feedback module and a second encoder, wherein the first angle feedback module, the first encoder, the second angle feedback module and the second encoder are all electrically connected with the control module, and the control module is also communicated with the laser system through a serial port line;
the image acquisition unit comprises a CCD image acquisition module, an image buffer, an FPGA processor and a communication module, and the CCD image acquisition module, the communication module and the image buffer are all electrically connected with the FPGA processor;
the coordinate correcting unit comprises a correcting calculation module and a correcting cache module, the correcting calculation module is respectively communicated with the communication module and the control module through serial ports, and the correcting cache module is electrically connected with the correcting calculation module through an IO port;
the correction calculation module is used for analyzing the photo data acquired by the image acquisition unit and performing correction calculation on the position coordinates of the laser irradiation point;
when the correction calculation module carries out correction calculation on the position coordinates of the laser irradiation points, firstly, a target point with a distance which does not accord with a preset error distance with a target point is screened out as a point to be corrected, the coordinates of the point to be corrected are recorded, then, the minimum step length of the horizontal direction stepping motor and the vertical direction stepping motor is taken as a unit, and the control module controls the laser emitted by the laser system reflected by the vibration mirror component to reflect the laser to the target plate in a row-column scanning mode to form a row-column matrix of a target point, and then selecting a target point closest to the target point as a correction point through the picture acquired by the image acquisition unit, recording the coordinates of the correction point and the corresponding coded data and angle data of the horizontal direction stepping motor and the vertical direction stepping motor to generate correction data, finally recording the correction data, and correcting the point to be corrected according to the correction data.
Preferably, the control module is an i.MX RT1052 type ARM controller, and the first angle feedback module and the second angle feedback module are both VTD68K08 type hollow angle sensors; the image buffer and the correction buffer module are both FLASH memories, the communication module is an MAX485 communication chip, the FPGA processor XILINX ZYNQ7000 FPG development board AX7Z020, the CCD image acquisition module is an LRCP _480P _720P _ PCBA type camera, the correction calculation module is an i.MX RT1052 type ARM controller, and the first encoder and the second encoder are both Emm _ V3.6.x stepping closed-loop drivers.
Preferably, the targets are arranged in an array.
Preferably, the first encoder is used for driving a horizontal stepping motor in the mirror vibration assembly, the encoder is used for driving a vertical stepping motor in the mirror vibration assembly, the first angle feedback module is used for acquiring rotation angle data of the horizontal stepping motor, and the second angle feedback module is used for acquiring rotation angle data of the vertical stepping motor.
Preferably, the drive encoding data of the first encoder, the drive encoding data of the second encoder, the first angle feedback module, the rotation angle data of the horizontal stepping motor, and the rotation angle data of the vertical stepping motor are collected and aggregated by a control module, and then sent to a correction calculation module to participate in correction calculation, and the result of the correction calculation is finally stored in a correction cache module.
Preferably, the CCD image acquisition module is configured to acquire photo data of the target board, the image buffer is configured to buffer the photo data, and the FPGA processor is configured to analyze the photo data.
Preferably, after the control module controls the vibrating mirror assembly to reflect laser to a target point or a target point, the CCD image acquisition module takes a picture, the CCD image acquisition module stores the taken pictures in the image buffer, the FPGA processor performs image processing to generate a comparison image, the correction calculation module calls the comparison image through the serial port bus, and identifies the pixel gray in the picture, thereby analyzing the distance between the target point and the target point.
Preferably, the correction calculation module is in communication with an external upper computer through a network cable.
The calibration module of the galvanometer scanning system solves the technical problem of high-precision calibration of the galvanometer, can find out all point positions to be corrected of the galvanometer and adjust the point positions by a software layer, reduces the defective rate, intelligently identifies the positions of laser transmission points, corrects by taking the minimum step length as a unit, achieves the maximum adjustment precision, finds correction points by a line scanning mode, does not need to participate in complex calculation, greatly simplifies the program design, and can achieve high-precision quick correction.
Drawings
FIG. 1 is a schematic diagram of the system architecture of the present invention;
FIG. 2 is a flow chart of the present invention for finding points to be corrected;
FIG. 3 is a flow chart of the correction of the present invention;
FIG. 4 is a schematic view of a target plate of the present invention;
FIG. 5 is a schematic illustration of a laser projected onto a target point under ideal conditions of the present invention;
FIG. 6 is a schematic diagram of laser projection onto a target in the practice of the present invention;
FIG. 7 is a schematic projection of an ideal correction point according to the present invention;
FIG. 8 is a schematic view of the invention with none of the correction points within the circular line;
FIG. 9 is a schematic illustration of the present invention with 2 correction points in the horizontal direction while inside the circular line;
FIG. 10 is a schematic view of the present invention with 4 correction points simultaneously within a circular line;
FIG. 11 is a schematic view of the present invention with 2 correction points in the vertical direction while inside the circular line;
in the figure: circular line 1, cross-shaped star line 2, substrate 3 and irradiation point 4.
Detailed Description
A calibration module of a galvanometer scanning system shown in fig. 1-11 includes a laser system and a galvanometer component, and further includes an image acquisition unit, a target plate, a coordinate correction unit and a galvanometer control unit, where the target plate includes a substrate 3, the substrate 3 is coated with a plurality of target points, laser light emitted by the laser system is reflected by the galvanometer component and then emitted to the target plate, and a laser irradiation point 4, i.e., a target point, is obtained;
as shown in FIG. 4, the target points are arranged in an array, the target points are the intersections of the cross-hairs 2 marked on the substrate 3, the target points in this embodiment are arranged in an 8 × 10 array, the row numbers are represented by numerals 1 to 10, the column numbers are represented by A, B, C, D, E, F, G and H, and the target point number of row 4, column 5 is D5.
In this embodiment, each target point is represented by a cross-shaped star line 2, a circular line 1 is marked by taking the intersection point of the cross-shaped star lines 2 as the center of a circle to represent a preset error distance, when the irradiation point 4 of the laser is in the circular line 1, the position of the irradiation point 4 of the laser is indicated to be correct, and when the irradiation point 4 of the laser is out of the circular line 1, the position of the irradiation point 4 of the laser is indicated to have deviation and needs to be corrected.
Due to the error of the mechanical structure and the error of the stepping motor, in the practical application process, the laser reflected by the galvanometer component cannot completely irradiate into each circular line 1, and some point positions can be irradiated outside the circular lines 1, so that the point positions are points to be corrected.
The galvanometer control unit comprises a control module, a first angle feedback module, a first encoder, a second angle feedback module and a second encoder, wherein the first angle feedback module, the first encoder, the second angle feedback module and the second encoder are all electrically connected with the control module, and the control module is also communicated with the laser system through a serial port line;
the first encoder is used for driving a horizontal direction stepping motor in the mirror vibration assembly, the encoder is used for driving a vertical direction stepping motor in the mirror vibration assembly, the first angle feedback module is used for acquiring the rotation angle data of the horizontal direction stepping motor, and the second angle feedback module is used for acquiring the rotation angle data of the vertical direction stepping motor.
And the drive encoding data of the first encoder, the drive encoding data of the second encoder, the first angle feedback module, the rotation angle data of the horizontal stepping motor and the rotation angle data of the vertical stepping motor are collected and aggregated by the control module, and then are sent to the correction calculation module to participate in correction calculation, and the result of the correction calculation is finally stored in the correction cache module.
The image acquisition unit comprises a CCD image acquisition module, an image buffer, an FPGA processor and a communication module, and the CCD image acquisition module, the communication module and the image buffer are all electrically connected with the FPGA processor;
the CCD image acquisition module is used for acquiring photo data of the target plate, the image buffer is used for caching the photo data, and the FPGA processor is used for analyzing and processing the photo data.
The control module controls the oscillator component to reflect laser to a target point or a target point, the CCD image acquisition module takes a picture, the CCD image acquisition module stores the taken pictures in the image buffer, the FPGA processor performs image processing to generate a comparison image, the correction calculation module calls the comparison image through the serial port bus and identifies the pixel gray level in the picture, and therefore the distance between the target point and the target point is analyzed.
The control module is an i.MX RT1052 type ARM controller, and the first angle feedback module and the second angle feedback module are both VTD68K08 type hollow angle sensors; the image buffer and the correction buffer module are both FLASH memories, the communication module is an MAX485 communication chip, the FPGA processor XILINX ZYNQ7000 FPG development board AX7Z020, the CCD image acquisition module is an LRCP _480P _720P _ PCBA type camera, the correction calculation module is an i.MX RT1052 type ARM controller, and the first encoder and the second encoder are both Emm _ V3.6.x stepping closed-loop drivers.
The coordinate correcting unit comprises a correcting calculation module and a correcting cache module, the correcting calculation module is respectively communicated with the communication module and the control module through serial ports, and the correcting cache module is electrically connected with the correcting calculation module through an IO port;
the correction calculation module is communicated with an external upper computer through a network cable.
The correction calculation module is used for analyzing the photo data acquired by the image acquisition unit and performing correction calculation on the position coordinates of the irradiation point 4 of the laser;
when the correction calculation module carries out correction calculation on the position coordinate of the irradiation point 4 of the laser, firstly, a target point with the distance which does not accord with the preset error distance with the target point is screened out as a point to be corrected, the coordinate of the point to be corrected is recorded, then, the minimum step length of the horizontal direction stepping motor and the vertical direction stepping motor is taken as a unit, and the control module controls the laser emitted by the laser system reflected by the vibration mirror component to reflect the laser to the target plate in a row-column scanning mode to form a row-column matrix of a target point, and then selecting a target point closest to the target point as a correction point through the picture acquired by the image acquisition unit, recording the coordinates of the correction point and the corresponding encoded data and angle data of the horizontal direction stepping motor and the vertical direction stepping motor to generate correction data, finally recording the correction data, and correcting the point to be corrected according to the correction data.
Fig. 6 shows a scene in which an error exists in the irradiation point 4 according to this embodiment, and the steps of the embodiment in this scene for correction are as follows:
step 1: and inputting the position information of the target plate to the correction calculation module through the upper computer, wherein the position information of the target plate comprises array arrangement information of the target points, number information of the target points and distance information between two adjacent target points.
Step 2: the coordinate of the target point with the number of A1 in the world coordinate system is sent to the correction calculation module through the upper computer, the correction calculation module carries out calibration calculation on the position of the galvanometer component according to the coordinate of the target point A1, the calibration calculation result is sent to the control module, and calibration of the galvanometer component is achieved through the control module.
And the control module informs the laser system to project the laser beam for calibration after controlling the galvanometer component to complete one action each time, and simultaneously sends laser projection information to the correction calculation module.
And step 3: after receiving the laser projection information, the correction calculation module sends a photographing instruction to the FPGA processor through the communication module, after receiving the photographing instruction, the FPGA processor controls the CCD image acquisition module to photograph a frame of picture on the target plate, the FPGA processor acquires the picture, and performs gray level processing and noise reduction processing on the picture to obtain a gray level picture;
and 4, step 4: the FPGA processor carries out row-column scanning on pixels in the gray level picture, identifies a crosshair star line 2, a round line 1 and a laser irradiation point 4 on a target plate, generates an identification result report, numbers the serial number of the gray level picture and stores the gray level picture in a buffer;
and 5: the correction calculation module calls the gray level picture and the identification result report corresponding to the gray level picture from the FPGA processor and displays the gray level picture and the identification result report to an operator through an upper computer, the operator manually adjusts the calibration parameters according to the gray level picture and the identification result report to enable the laser beam to be aligned with the target point A1, and after the operator confirms that the laser beam is aligned with the target point A1, the operator sends an automatic calibration instruction to the correction calculation module through the upper computer;
in the embodiment, the purpose of steps 2 to 5 is to align the laser beam with the first target point, namely the target point a1, and the establishment of the world coordinate system is determined by the position of the target plate on the processing platform of the 3D printer.
Step 6: after receiving the automatic calibration instruction, the correction calculation module calculates rotation angle data of the galvanometer component through a trigonometric function model according to array arrangement information of the target points, number information of the target points and distance information between two adjacent target points and the sequence of line scanning and the number of the target points in sequence to generate a rotation angle data set and sends the rotation angle data set to the control module;
the calculation of the rotation angle data of the galvanometer component through the trigonometric function model is a basic calculation method of the galvanometer, and is not described in detail because the method is the prior art.
In this embodiment, the rotation angle data is used to control the rotation angles of the horizontal stepping motor and the vertical stepping motor in the galvanometer assembly, and the laser beam is projected to the corresponding target point through the rotation angle coordination of the horizontal stepping motor and the vertical stepping motor.
And 7: the control module controls the horizontal stepping motor and the vertical stepping motor to rotate according to the rotation angle data set, drives the galvanometer to change the reflection angle of the laser beam, so that the laser beam is sequentially projected on a target point, and the control module wants to modify the calculation module to feed back projection completion information when the projection action of one target point is completed.
Ideally, as shown in fig. 5, the projection of the laser beams onto the target point is controlled by the calculated rotation angle data, wherein each laser beam is projected into the circular line 1, i.e. the projection position of each laser beam is correct. However, in actual use, not all laser beams can be projected to the correct position, as shown in fig. 4, where the projected positions of the target points a2, A3, a4, a5, a6, a7, A8 and a9 all have deviations, fig. 4 is a schematic diagram, and only the above target points do not have to be deviated in the actual use process, so that the projection of the above target points needs to be corrected at this time.
And 8: the correction calculation module sends a photographing instruction to the FPGA processor after receiving the projection completion information, and the FPGA processor controls the CCD image acquisition module to photograph the target plate after receiving the photographing instruction;
and step 9: the FPGA processor processes the photos according to the method principle of the step 3 and the step 4, and shoots each projection action once to obtain a photo set, a serial number code of each photo and a corresponding recognition result report;
step 10: the correction calculation module calls a photo set, identifies each photo according to the serial number code of each photo and the corresponding identification result report, analyzes whether the irradiation point 4 of the laser on each photo is in the corresponding circular line 1, and simultaneously records the irradiation point 4 of the laser as a target point: if within the circular line 1, step 11 is performed; if the line is not in the circular line 1, executing a step 12, namely entering a correction process;
step 11: sequentially selecting the next photo according to the serial number of the photo, and re-executing the step 10 until all the photos in the photo set are subjected to position recognition, and ending;
step 12: entering a correction process, and specifically comprising the following steps:
step S12-1: establishing a temporary coordinate system by taking the target point as an origin;
step S12-2: calculating rotation angle data of new target points by taking the minimum step length of a horizontal stepping motor and a vertical stepping motor as a minimum unit, establishing a projection rotation angle data set, controlling the horizontal stepping motor and the vertical stepping motor to rotate by a control module according to the projection rotation angle data set to enable a laser beam to project a plurality of new target points, wherein the new target points are distributed in a matrix form, the projection sequence of the new target points is carried out according to a row-column scanning sequence, and the distance between two adjacent new target points is determined by the rotation angle of the minimum step length of the horizontal stepping motor and the vertical stepping motor, namely the minimum precision of the galvanometer;
step S12-3: according to the method principle of the step 3 and the step 4, shooting a frame of picture of each new target point through a CCD camera to obtain a picture set of the new target point;
step S12-4: according to the method principle of the step 9, the correction calculation module analyzes the new target point photos one by one, finds out the target point positioned in the circular line 1, and records the target point as a correction point;
step 12-5: the correction calculation module records the serial number codes of the photos corresponding to the correction points, correspondingly finds out the corresponding rotation angle data in the projection rotation angle data set through the serial number codes, and marks the rotation angle data as correction rotation angle data;
the control module obtains the actual corner of horizontal stepping motor, namely the horizontal corner through first angle feedback module, obtains the actual corner of vertical stepping motor, namely the vertical corner through second angle feedback module simultaneously, and control module sends horizontal corner and vertical corner for the correction calculation module to save to show for operating personnel through the host computer, use when being used for artifical correction.
Step 12-6: the correction point is corrected based on the correction rotation angle data, that is, the correction rotation angle data is updated as projection rotation angle data of the correction point.
As shown in fig. 7, for an ideal correction process, where the target point a5 is a point to be corrected, and the correction calculation module sequentially calculates the positions of the target point W1, the target point W2, the target point W3 and the target point W4 by using the minimum step size of the horizontal stepping motor and the vertical stepping motor as the minimum unit, that is, the angles that should be selected respectively by the horizontal stepping motor and the vertical stepping motor, in this embodiment, for the target point W1, the target point W2, the target point W3 and the target point W4, the horizontal stepping motor selects according to the step size during rotation, and the projection of the target point W1, the target point W2, the target point W3 and the target point W4 by the laser beam can be realized without selecting by the vertical stepping motor.
After the projection of the target point W4 is completed, the vertical stepping motor rotates by an angle of one step to reach the next line, namely the X line, and then the scanning projection of the W line, the X line, the Y line and the Z line is completed according to the sequence of the target point X4, the target point X3, the target point X2 and the target point X1, namely the sequence of line-column scanning.
When the projection of a target point is finished, the correction calculation module immediately informs the image acquisition unit to shoot a frame of picture, finds out a target point in the circular line 1 of the target by analyzing the gray-scale image of the picture, such as the target point Y2 in FIG. 7, takes the target point Y2 as a correction point, finds out rotation angle data of the correction point in the projection rotation angle data set according to the serial number of the picture corresponding to the correction point, namely rotation angles and encoded data respectively corresponding to the horizontal stepping motor and the vertical stepping motor, and performs correction updating according to the rotation angle data.
In step S12-4, the following situations may occur during the actual analysis of the picture:
case 1: as shown in fig. 8, all correction points are not in the circular line 1, the correction calculation module sends correction precision alarm information to an operator through the upper computer, and the operator performs manual adjustment according to actual conditions.
Case 2: if there are a plurality of correction points in the circle, the irradiation point 4 closest to the origin of the temporary coordinate system is selected as a correction point and corrected, and the correction points are selected as the target point Y2, the target point X2, and the target point X2, respectively, as shown in fig. 9, 10, and 11.
The invention can repeatedly utilize the related procedures of image processing adopted in the image acquisition unit, greatly facilitates the compiling process of the software flow and realizes the optimization of the correction flow.
The calibration module of the galvanometer scanning system solves the technical problem of high-precision calibration of the galvanometer, can find out all point positions to be corrected of the galvanometer and adjust the point positions by a software layer, reduces the defective rate, intelligently identifies the positions of laser transmission points, corrects by taking the minimum step length as a unit, achieves the maximum adjustment precision, finds correction points by a line scanning mode, does not need to participate in complex calculation, greatly simplifies the program design, and can achieve high-precision quick correction.
Claims (8)
1. A calibration module of a galvanometer scanning system comprises a laser system and a galvanometer component, and is characterized in that: the laser system comprises a target plate, an image acquisition unit, a target plate, a coordinate correction unit and a galvanometer control unit, wherein the target plate comprises a substrate (3), a plurality of target points are coated on the substrate (3), laser rays emitted by the laser system are reflected by the galvanometer component and then emitted to the target plate to obtain a laser irradiation point (4), namely a target point;
the galvanometer control unit comprises a control module, a first angle feedback module, a first encoder, a second angle feedback module and a second encoder, wherein the first angle feedback module, the first encoder, the second angle feedback module and the second encoder are all electrically connected with the control module, and the control module is also communicated with the laser system through a serial port line;
the image acquisition unit comprises a CCD image acquisition module, an image buffer, an FPGA processor and a communication module, and the CCD image acquisition module, the communication module and the image buffer are all electrically connected with the FPGA processor;
the coordinate correcting unit comprises a correcting calculation module and a correcting cache module, the correcting calculation module is respectively communicated with the communication module and the control module through serial ports, and the correcting cache module is electrically connected with the correcting calculation module through an IO port;
the correction calculation module is used for analyzing the photo data acquired by the image acquisition unit and performing correction calculation on the position coordinates of the irradiation point (4) of the laser;
when the correction calculation module carries out correction calculation on the position coordinate of the irradiation point (4) of the laser, firstly, a target point with a distance which does not accord with a preset error distance from the target point is screened out as a point to be corrected, the coordinate of the point to be corrected is recorded, a temporary coordinate system is established by taking the point to be corrected as an original point, then the minimum step length of a horizontal stepping motor and a vertical stepping motor is taken as a unit, the control module controls the laser emitted by a laser system of a vibrating mirror component, so that the laser is reflected on the target plate in a row-column scanning mode to form a row-column matrix of the target point, then the picture acquired by an image acquisition unit selects the target point closest to the target point as the correction point, the coordinate of the correction point and the corresponding encoded data and angle data of the horizontal stepping motor and the vertical stepping motor are recorded, and correction data are generated, and finally, recording correction data, and correcting the point to be corrected according to the correction data.
2. A calibration module for a galvanometer scanning system, as defined in claim 1, wherein: the control module is an i.MX RT1052 type ARM controller, and the first angle feedback module and the second angle feedback module are both VTD68K08 type hollow angle sensors; the image buffer and the correction buffer module are both FLASH memories, the communication module is an MAX485 communication chip, the FPGA processor XILINX ZYNQ7000 FPG development board AX7Z020, the CCD image acquisition module is an LRCP _480P _720P _ PCBA type camera, the correction calculation module is an i.MX RT1052 type ARM controller, and the first encoder and the second encoder are both Emm _ V3.6.x stepping closed-loop drivers.
3. A calibration module for a galvanometer scanning system, as defined in claim 1, wherein: the target points are arranged in an array.
4. A calibration module for a galvanometer scanning system, as defined in claim 1, wherein: the first encoder is used for driving a horizontal direction stepping motor in the mirror vibration assembly, the encoder is used for driving a vertical direction stepping motor in the mirror vibration assembly, the first angle feedback module is used for acquiring the rotation angle data of the horizontal direction stepping motor, and the second angle feedback module is used for acquiring the rotation angle data of the vertical direction stepping motor.
5. The calibration module of a galvanometer scanning system of claim 4, wherein: and the drive encoding data of the first encoder, the drive encoding data of the second encoder, the first angle feedback module, the rotation angle data of the horizontal stepping motor and the rotation angle data of the vertical stepping motor are collected and aggregated by the control module, and then are sent to the correction calculation module to participate in correction calculation, and the result of the correction calculation is finally stored in the correction cache module.
6. A calibration module for a galvanometer scanning system, as defined in claim 1, wherein: the CCD image acquisition module is used for acquiring photo data of the target plate, the image buffer is used for caching the photo data, and the FPGA processor is used for analyzing and processing the photo data.
7. A calibration module for a galvanometer scanning system according to claim 6, wherein: the control module controls the oscillator component to reflect laser to a target point or a target point, the CCD image acquisition module takes a picture, the CCD image acquisition module stores the taken pictures in the image buffer, the FPGA processor performs image processing on the pictures to generate a comparison image, the correction calculation module calls the comparison image through the serial port bus and identifies the pixel gray level in the picture, and therefore the distance between the target point and the target point is analyzed.
8. A calibration module for a galvanometer scanning system, as defined in claim 1, wherein: the correction calculation module is communicated with an external upper computer through a network cable.
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