WO2024007587A1 - 一种用于dlp3d打印的智能校正控制方法 - Google Patents

一种用于dlp3d打印的智能校正控制方法 Download PDF

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Publication number
WO2024007587A1
WO2024007587A1 PCT/CN2023/075902 CN2023075902W WO2024007587A1 WO 2024007587 A1 WO2024007587 A1 WO 2024007587A1 CN 2023075902 W CN2023075902 W CN 2023075902W WO 2024007587 A1 WO2024007587 A1 WO 2024007587A1
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Prior art keywords
correction
optical machine
optical
control module
full
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PCT/CN2023/075902
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English (en)
French (fr)
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岳焕焕
王林
施坜圆
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南京铖联激光科技有限公司
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Publication of WO2024007587A1 publication Critical patent/WO2024007587A1/zh

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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
    • 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
    • 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
    • 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

Definitions

  • the present invention relates to the technical field of 3D printing systems, and in particular, to an intelligent correction control method for DLP 3D printing.
  • DLP technology is a rapid prototyping technology that uses a projector to solidify photosensitive polymer liquid layer by layer to create 3D printed objects.
  • This molding technology first uses slicing software to cut the model into thin slices, and the projector plays the slide show. Each layer of the image produces a photopolymerization reaction and solidifies in the area where the resin layer is very thin, forming a thin layer of the part. Then the molding table moves one layer. The projector continues to play the next slide and continues to process the next layer. This cycle continues until the end of printing. Therefore, not only the molding accuracy is high, but the printing speed is also very fast.
  • DLP-based 3D printing equipment has become the most common 3D printer product on the market. This technology not only has high printing accuracy, reaching the micron level, but also the surface of the models printed with this type of equipment is very smooth and delicate, far exceeding other molding technologies. At the same time, the printing speed of this type of equipment is also very fast, and it is one of the fastest molding products among common equipment on the market.
  • the core advantages of DLP 3D printers are high precision and fast printing speed.
  • the accuracy of DLP3D printer equipment directly determines the printing accuracy.
  • x represents the horizontal axis
  • y represents the vertical axis
  • z represents the vertical axis.
  • the dimensional deviation in any of the three directions will lead to overall accuracy distortion.
  • the Z-axis and the XY-axis are completely different and need to be viewed separately.
  • the Z-axis accuracy is determined by the Z-axis module accuracy
  • the X-axis and Y-axis accuracy are determined by the optical-mechanical accuracy.
  • the accuracy error of a few microns in the Z-axis is negligible. What actually affects the printing quality is the resolution on the XY surface, so If there is a slight error in the optical path, the model will be distorted and distorted, resulting in inaccurate accuracy.
  • XY calibration errors are a common cause of accuracy distortion.
  • the present invention provides an intelligent correction control method for DLP 3D printing, which greatly improves printing accuracy and printing quality.
  • an intelligent correction control method for DLP 3D printing includes the following steps:
  • Projection size correction The control module outputs a full-frame signal to the optical machine, and the optical machine projects the full-frame signal to the molding platform. By checking the projection size, the installation height of the optical machine is adjusted;
  • Projection focus correction The control module outputs the focusing picture signal to the optical machine, and the optical machine projects the focusing picture signal to the molding platform. By shooting the projected focusing picture, the optical machine installation focus is confirmed;
  • Illumination uniformity correction The control module outputs a full-white full-frame signal to the optical machine.
  • the optical machine projects the illumination uniformity correction image to the molding platform. By measuring the illumination uniformity, the illumination of each correction area of the image is corrected, thereby performing optical machine output.
  • Projection deformity correction The control module imports the correction block slice data, turns on printing, and the control module outputs the correction block slice data to the optical machine.
  • the optical machine projects the correction block slice data layer by layer to the molding platform, forms the correction block layer by layer, and measures the correction block. size, perform optical-mechanical (1) projection deformity correction.
  • the intelligent correction control method for DLP 3D printing also includes: optical machine output optical power correction: the control module outputs a full-white full-frame signal to the optical machine, and the optical machine projects the full-white full-frame signal to the molding Platform, the optical machine output optical power is corrected by collecting the optical machine output optical power.
  • the resolution needs to be changed before step 1); the optical machine and the control module are connected through an HDMI high-definition line, and the control module changes the resolution of the HDMI high-definition line to match the initial resolution of the optical machine, so that the optical machine Able to identify the image signal input by the control module.
  • step 1) projection size correction are:
  • B. Determine the measured value and the size of the full frame scheduled by the optical machine. If the measured value is larger than the full frame size scheduled by the optical machine, adjust the installation of the optical machine and move the adjustment device upward to reduce the distance between the optical machine and the forming platform, thereby making the optical machine The size of the entire projected image is reduced; if the measured value is smaller than the predetermined full-frame size of the optical engine, adjust the installation of the optical engine and move the adjustment device downward to increase the distance between the optical engine and the molding platform, thereby increasing the size of the full image projected by the optical engine. ;
  • step B Repeat step B again until the size of the full image projected by the optical machine matches the predetermined full image size.
  • step 2) projection focus correction includes the following steps:
  • Step 2) Projection focus correction includes the following steps:
  • the digital camera determines the contrast transfer function values of the four corners and the center area of the projected focus picture by shooting the projected focus picture;
  • the control module outputs a signal to the front group motor, and the front group motor drives the front group adjustment of the lens until the contrast transfer function value at the four corners of the focusing screen ⁇ a 0 ; If the contrast transfer function value in the center area of the focusing screen is ⁇ a 0 , the control module outputs a signal to the rear group motor, and the rear group motor drives the rear group adjustment of the lens until the contrast transfer function value in the center area of the focusing screen ⁇ a 0 ; If the contrast transfer function value at the four corners of the focusing screen is ⁇ a 0 , and the contrast transfer function value in the center area of the focusing screen is ⁇ a 0 , then the optical-mechanical installation focus is qualified.
  • step 3) illumination uniformity correction includes the following steps:
  • the illumination is greater than the specific value b 0 , the corresponding gray value of the area is increased, so that the illumination uniformity measurement error of each grid is less than 5%.
  • step 4) projection deformity correction includes the following steps:
  • the control module outputs the standard correction block slicing data to the optical machine, turns on the UV LED to start curing, and the optical machine projects the correction block slicing data to the molding platform layer by layer, forming the correction block layer by layer;
  • ii Measure the front, rear, left, and right dimensions of the projected correction block. If the front and rear dimensions of the correction block are inconsistent, adjust the optical machine installation and adjustment device to make the projected correction block have the same front and rear dimensions. If the left and right dimensions of the correction block are inconsistent, adjust the optical machine installation and adjustment. The device makes the left and right sizes of the projected correction blocks consistent.
  • the optical machine output optical power is corrected, the optical machine output optical power is collected by a light sensor, and the optical machine output optical power correction is completed by adjusting the brightness of the LED.
  • the brightness of the LED 1000 ⁇ (the current value of the LED) / 30.0.
  • the invention has positive effects: the invention simplifies the debugging process, makes the DLP 3D printing process intelligent, quantifies debugging standards, reduces the error rate of X-axis and Y-axis calibration, and greatly improves printing accuracy and printing quality.
  • Figure 1 is an overall flow chart of the method of the present invention
  • Figure 2 is a schematic structural diagram of the optical path of the present invention.
  • Figure 3 is a flow chart of projection size correction according to the present invention.
  • Figure 4 is a flow chart of projection focus correction according to the present invention.
  • Figure 5 is an enlarged schematic diagram of the four corners and central area of the focusing screen according to the present invention.
  • Figure 6 is a schematic diagram of a focus-adjusted screen projected by the present invention.
  • Figure 7 is a schematic diagram of the standard calibration block printout.
  • the present invention discloses an intelligent correction control method for DLP 3D printing.
  • the method includes the following steps:
  • Projection size correction The control module 9 outputs a full-frame signal to the optical machine 1, and the optical machine 1 projects the full-frame signal to the molding platform 7. By checking the projection size, the installation height of the optical machine 1 is adjusted; where, the control Module 9 is used to send control commands and output various signals; the forming platform 7 is the receiving end of the output of the optical machine 1. The height adjustment accuracy of the optical machine 1 directly determines the dimensional accuracy of the printed parts in the XY direction.
  • the control module 9 outputs the focusing picture signal to the optical machine 1, and the optical machine 1 projects the focusing picture signal to the molding platform 7.
  • the focus screen is a picture designed to confirm whether it is focused.
  • the enlargement diagram shown in Figure 5 includes black and white lines. The line width and spacing are 1 pixel. If it is not focused, the image will be blurry after being enlarged by a camera with 1000 times magnification. Yes, no lines can be seen.
  • Illumination uniformity correction The control module 9 outputs a full-white full-frame signal to the optical machine 1, and the optical machine 1 projects the illumination uniformity correction picture to the molding platform 7, and performs the process by measuring the illumination of each correction area of the illumination uniformity correction picture.
  • the uniformity of the illumination output of the optical machine 1 is corrected; the uniformity of the illumination output of the optical machine 1 directly determines the printing accuracy and printing efficiency of the printed parts.
  • the illumination uniformity correction picture is an all-white picture evenly divided into small squares with 5 rows and 10 columns. Each grid is a correction area.
  • the light sensor 8 is placed in the corresponding grid and can measure the light intensity in the grid area.
  • the hood file is The PNG format is stored in a cache memory. Each time the projected image is superimposed with a light hood, it can ensure that the light and shade of the light machine 1 are consistent, that is, the illumination is uniform.
  • the control module 9 imports the correction block slice data and starts printing.
  • the control module 9 outputs the correction block slice data to the optical machine 1.
  • the optical machine 1 projects the correction block slice data to the molding platform 7 layer by layer, and performs molding and correction layer by layer. block, measure the size of the correction block, and perform optical machine 1 projection deformity correction.
  • the vertical adjustment of the optical machine 1 can be realized through the optical machine installation and adjustment device 6.
  • the accuracy of the optical machine projection deformity correction directly determines the dimensional accuracy of the printed parts in the XY direction.
  • the correction block slicing data is a 3D graphic designed using external 3D drawing software and sliced using slicing software.
  • the projection direction of the optical machine 1 needs to be kept perpendicular to the projection surface, otherwise the projection trapezoidal phenomenon will occur.
  • the resolution needs to be changed before step 1); the optical machine 1 and the control module 9 are connected through an HDMI high-definition line, and the control module 9 changes the resolution of the HDMI high-definition line to match the initial resolution of the optical machine 1, so that the optical machine 1 can recognize the control The image signal input by module 9.
  • step 1) projection size correction are:
  • B. Determine the size of the measured value and the predetermined full-frame size of optical machine 1. If the measured value is larger than the predetermined full-frame size of optical machine 1, When the surface size is large, adjust the optical machine installation and adjustment device 6 to move upward, so that the distance between the optical machine 1 and the forming platform 7 is reduced, thereby reducing the size of the full picture projected by the optical machine 1; The surface size is small, and the optical machine installation and adjustment device 6 are adjusted to move downward, so that the distance between the optical machine 1 and the forming platform 7 is increased, thereby increasing the size of the entire image projected by the optical machine 1;
  • step B again until the size of the full picture projected by the optical machine 1 matches the predetermined full picture size.
  • the projection distance of the optical machine 1 is directly proportional to the size of the projected image of the optical machine 1. That is, if the optical machine 1 is far from the molding platform 7, the projection size will be too large. If the optical machine 1 is close to the molding platform 7, the projection size will be small.
  • the optical machine 1 predetermines a full picture, which is the full picture output by the control module 9 .
  • step 2) projection focus correction includes the following steps:
  • the digital camera 10 determines the contrast transfer function values of the four corners and the center area of the projected focus picture by photographing the projected focus picture ( Figure 6);
  • the control module 9 If the contrast transfer function value (CTF) of the four corners of the focusing screen (P13, P14, P15, P16) is ⁇ a 0 , the control module 9 outputs a signal to the front group motor 2, and the front group motor 2 drives the lens front group 3 Adjust until the contrast transfer function value at the four corners of the focusing screen ⁇ a 0 ; if the contrast transfer function value in the center area (P6) of the focusing screen is ⁇ a 0 , the control module 9 outputs a signal to the rear group motor 5, and the rear group motor 5.
  • CTF contrast transfer function value
  • the focus motor includes a front group motor 2 and a rear group motor 5 .
  • the specific value a 0 is the qualification standard for the contrast transfer function value of the optical machine 1.
  • Step 3) Illumination uniformity correction includes the following steps:
  • the light sensor 8 is placed above each grid.
  • the light sensor 8 measures the output illumination, and the control module 9 outputs the illumination reading.
  • Fetch instructions to obtain the correct reading value of the light sensor 8, and compare the output illumination with a specific value b 0 ;
  • the specific value b 0 is the qualification standard for the illumination of light machine 1.
  • Step 4) Projection deformity correction includes the following steps:
  • the control module 9 inputs the first layer image through the HDMI high-definition line, that is, outputs the standard correction block slicing data to the optical machine 1, turns on the UV LED (ultraviolet light emitting diode) to start curing, and the optical machine 1 projects the correction block slicing data layer by layer to the molding Platform 7, forming correction blocks layer by layer;
  • ii Measure the front, rear, left, and right dimensions of the projected correction block. If the front and rear dimensions of the correction block are inconsistent, adjust the optical machine installation and adjustment device 6 so that the projected correction block has the same front and rear dimensions. If the left and right dimensions of the correction block are inconsistent, adjust the optical machine installation and adjustment device 6. The adjusting device 6 makes the left and right sizes of the projected correction blocks consistent.
  • the standard correction block slice data is a standard 60 ⁇ 120 standard block slice file.
  • the first screw 11 adjusts the first screw 11 and rotate the optical machine 1 at a certain angle around the Y axis relative to the forming platform 7.
  • make the projected size consistent before and after if the left is larger than the right, adjust the second screw 12, and rotate the optical machine 1 relative to the forming platform 7 at a certain angle around the

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Abstract

本发明涉及3D打印系统技术领域，尤其涉及一种用于DLP3D打印的智能校正控制方法，方法包括步骤：首先投影尺寸校正；然后进行投影聚焦校正；接着进行光照度均匀性校正；最后完成投影畸形校正。本发明提高了打印件XY方向的尺寸精度。

Description

一种用于DLP3D打印的智能校正控制方法 技术领域
本发明涉及3D打印系统技术领域，尤其涉及一种用于DLP3D打印的智能校正控制方法。
背景技术
DLP技术主要是通过投影仪来逐层固化光敏聚合物液体，从而创建出3D打印对象的一种快速成型技术。这种成型技术首先利用切片软件把模型切薄片，投影机播放幻灯片，每一层图像在树脂层很薄的区域产生光聚合反应固化，形成零件的一个薄层，然后成型台移动一层，投影机继续播放下一张幻灯片，继续加工下一层，如此循环，直达打印结束，所以不但成型精度高，而且打印速度也非常快。
基于DLP的3D打印设备，已成为目前市场上最常见3D打印机产品。该技术不仅打印精度高，可达微米级，用此类设备打印出来的模型表面非常光滑细腻，远超其他成型技术。同时，该类设备打印速度也非常快，是目前市面上常见设备里成型速度最快的产品类型之一。
目前，DLP型3D打印机的核心优势是精度高，打印速度快。DLP3D打印机设备精度直接决定了打印精度，空间直角坐标系中：x代表横轴，y代表纵轴，z代表竖轴，3个方向任何一处的尺寸偏差都会导致整体的精度失真。因为成型平台的移动方式，Z轴与XY轴完全不同，需要分开来看。其中Z轴精度由Z轴模组精度决定，X轴和Y轴精度由光机精度决定，Z轴几微米的精度误差可以忽略不计，实际影响打印质量的则是XY面上的分辨率，所以光路有微小的误差，模型就会扭曲和失真，造成精度不准，XY校准错误是导致精度失真的常见原因。
发明内容
本发明提供了一种用于DLP3D打印的智能校正控制方法，极大的提高了打印精度和打印质量。
为了实现本发明的目的，所采用的技术方案是：一种用于DLP3D打印的智能校正控制方法，方法包括如下步骤：
1)投影尺寸校正：控制模块输出全幅画面信号给光机，光机投射全幅画面信号至成型平台，通过对投影尺寸的检查，进行光机安装高度的调校；
2)投影聚焦校正：控制模块输出调焦画面信号给光机，光机投射调焦画面信号至成型平台，通过拍摄投影的调焦画面，进行光机安装聚焦的确认；
3)光照度均匀性校正：控制模块输出全白满幅画面信号给光机，光机投射光照度均匀性校正画面至成型平台，通过测量光照度均匀性校正画面各个校正区域的光照度，从而进行光机输出光照度均匀性校正；
4)投影畸形校正：控制模块导入校正块切片数据，开启打印，控制模块输出校正块切片数据给光机，光机逐层投射校正块切片数据至成型平台，逐层成型校正块，测量校正块尺寸，进行光机(1)投影畸形校正。
作为本发明的优化方案，用于DLP3D打印的智能校正控制方法还包括，光机输出光功率校正：控制模块输出全白满幅画面信号给光机，光机投射全白满幅画面信号至成型平台，通过采集光机输出光功率进行光机输出光功率校正。
作为本发明的优化方案，在步骤1)之前需要变更解析度；光机与控制模块通过HDMI高清线相连，控制模块变更HDMI高清线的解析度从而与光机初始解析度相匹配，使得光机能够识别控制模块输入的影像信号。
作为本发明的优化方案，步骤1)投影尺寸校正的具体步骤为：
A、测量成型平台上的投影全幅画面尺寸，包括X方向和Y方向的测量值；
B、判断测量值和光机预定全幅画面尺寸大小，如测量值比光机预定全幅面面尺寸大，调节光机安装及调节装置上移，使光机和成型平台距离减小，从而使光机投射全幅画面尺寸减小；如测量值比光机预定全幅面面尺寸小，调节光机安装及调节装置下移，使光机和成型平台距离增大，从而使光机投射全幅画面尺寸增大；
C、再次重复步骤B，直至光机投射全幅画面尺寸与预定全幅画面尺寸相符。
作为本发明的优化方案，步骤2)投影聚焦校正包括如下步骤：
步骤2)投影聚焦校正包括如下步骤：
a、数字摄像头通过拍摄投影的调焦画面，判定投影的调焦画面四个角落以及中心区域的对比度传递函数值；
b、若调焦画面四个角落的对比度传递函数值＜a0，控制模块输出信号给前群马达，前群马达带动镜头前群调整，直至调焦画面四个角落的对比度传递函数值≥a0；若调焦画面中心区域的对比度传递函数值＜a0，控制模块输出信号给后群马达，后群马达带动镜头后群调整，直至调焦画面中心区域的对比度传递函数值≥a0；若若调焦画面四个角落的对比度传递函数值≥a0，并且调焦画面中心区域的对比度传递函数值≥a0，则光机安装聚焦合格。
作为本发明的优化方案，步骤3)光照度均匀性校正包括如下步骤：
Ⅰ、将光照度均匀性校正画面按照行列分成若干格子，光传感器置于各个格子的上方，光传感器测量输出光照度，输出光照度与特定值b0比较；
Ⅱ、若光照度＞特定值b0，则增加该区域对应的灰度值，最终使得每个格子的光照度均匀性测量值误差小于5％。
作为本发明的优化方案，步骤4)投影畸形校正包括如下步骤：
ⅰ、控制模块输出标准校正块切片数据给光机，开启UV LED开始固化，光机逐层投射校正块切片数据至成型平台，逐层成型校正块；
ⅱ、测量投影的校正块前后左右四个方向尺寸，若校正块前后尺寸不一致，调节光机安装及调节装置使得投影的校正块前后尺寸一致；若校正块左右尺寸不一致，调节光机安装及调节装置使得投影的校正块左右尺寸一致。
作为本发明的优化方案，光机输出光功率校正时，光机输出光功率通过光传感器采集，光机输出光功率校正通过调整LED的亮度来完成。
作为本发明的优化方案，LED的亮度＝1000×(LED的电流值)/30.0。
本发明具有积极的效果：本发明简化了调试过程，使得这个DLP3D打印流程实现了智能化，量化了调试标准，减少了X轴和Y轴校准的错误率，极大的提高了打印精度和打印质量。
附图说明
下面结合附图和具体实施方式对本发明作进一步详细的说明。
图1是本发明方法的整体流程图；
图2是本发明光路的结构示意图；
图3是本发明投影尺寸校正流程图；
图4是本发明投影聚焦校正的流程图；
图5是本发明调焦画面四个角落和中心区域的放大示意图；
图6是本发明投影的调焦画面的示意图；
图7是为标准校正块打印件示意图。
其中：1、光机，2、前群马达，3、镜头前群，4、镜头后群，5、后群马达，6、 光机安装及调节装置，7、成型平台，8、光传感器，9、控制模块，10、数字摄像头，11、第一螺丝，12、第二螺丝。
具体实施方式
如图1和2所示，本发明公开了一种用于DLP3D打印的智能校正控制方法，方法包括如下步骤：
1)投影尺寸校正：控制模块9输出全幅画面信号给光机1，光机1投射全幅画面信号至成型平台7，通过对投影尺寸的检查，进行光机1安装高度的调校；其中，控制模块9用于发送操控命令和输出各种信号；成型平台7为光机1输出的接收端。光机1高度调校精度直接决定了打印件XY方向的尺寸精度。
2)投影聚焦校正：控制模块9输出调焦画面信号给光机1，光机1投射调焦画面信号至成型平台7，通过拍摄投影的调焦画面，进行光机1安装聚焦的确认；其中，光机1的投影聚焦校正程度决定了打印件的精细程度。调焦画面为确认是否聚焦而设计的图片，如图5所示的放大示意图，包括黑白相间的线，线条宽和间距为1pixel，如果不聚焦，图像在1000倍放大的摄像头下放大后是模糊的，看不到线条。
3)光照度均匀性校正：控制模块9输出全白满幅画面信号给光机1，光机1投射光照度均匀性校正画面至成型平台7，通过测量光照度均匀性校正画面各个校正区域的光照度从而进行光机1输出光照度均匀性校正；光机1输出的光照度均匀性程度直接决定了打印件的打印精度和打印效率。光照度均匀性校正画面，是全白满幅画面被均匀的分割成5行10列的小方格，每个格子为一个校正区域，光传感器8放在对应格子内，可以测量该格区域内的光照度，各区域不同时，就需要把光照度较大的区域暗化，即调灰度值，直到各处光照度一致，此带有不同灰度值的图片会作为遮光罩使用，遮光罩档案是以PNG格式储存在一个快取记忆体中，每次投射的画面叠加遮光罩，即可保证光机1各处的明暗度一致，即光照度均匀。
4)投影畸形校正：控制模块9导入校正块切片数据，开启打印，控制模块9输出校正块切片数据给光机1，光机1逐层投射校正块切片数据至成型平台7，逐层成型校正块，测量校正块尺寸，进行光机1投影畸形校正。光机1垂直度调校可通过光机安装及调节装置6来实现，光机投影畸形校正精度直接决定了打印件XY方向的尺寸精度。其中，校正块切片数据是利用外部3D绘图软件设计的3D图形，用切片软件切片。光机1的投影方向与投影面需保持垂直，否则会出现投影梯形现象。
用于DLP3D打印的智能校正控制方法还包括，光机1输出光功率校正：控制模块9输出全白满幅画面信号给光机1，光机1投射全白满幅画面信号至成型平台7，通过采集光机1输出光功率进行光机1输出光功率校正。光机1输出光功率直接决定了打印效率。光机1输出光功率校正时，光机1输出光功率通过光传感器8采集，光机1输出光功率校正通过调整LED的亮度来完成。LED的亮度＝1000×(LED的电流值)/30.0。通过调节光机1中的LED电流可以校正机1输出光功率。
在步骤1)之前需要变更解析度；光机1与控制模块9通过HDMI高清线相连，控制模块9变更HDMI高清线的解析度与光机1初始解析度相匹配，使得光机1能够识别控制模块9输入的影像信号。
如图3所示，步骤1)投影尺寸校正的具体步骤为：
A、测量成型平台7上的投影全幅画面尺寸，包括X方向和Y方向的测量值；
B、判断测量值和光机1预定全幅画面尺寸大小，如测量值比光机1预定全幅 面面尺寸大，调节光机安装及调节装置6上移，使光机1和成型平台7距离减小，从而使光机1投射全幅画面尺寸减小；如测量值比光机1预定全幅面面尺寸小，调节光机安装及调节装置6下移，使光机1和成型平台7距离增大，从而使光机1投射全幅画面尺寸增大；
C、再次重复步骤B，直至光机1投射全幅画面尺寸与预定全幅画面尺寸相符。其中，光机1投影距离与光机1投射画面尺寸成正比关系，即光机1距离成型平台7远，投影尺寸偏大，光机1距离成型平台7近，投影尺寸偏小。光机1预定全幅画面即控制模块9输出的全幅画面。
如图4所示，步骤2)投影聚焦校正包括如下步骤：
a、数字摄像头10通过拍摄投影的调焦画面(图6)，判定投影的调焦画面四个角落以及中心区域的对比度传递函数值；
b、若调焦画面四个角落(P13、P14、P15、P16)的对比度传递函数值(CTF)＜a0，控制模块9输出信号给前群马达2，前群马达2带动镜头前群3调整，直至调焦画面四个角落的对比度传递函数值≥a0；若调焦画面中心区域(P6)的对比度传递函数值＜a0，控制模块9输出信号给后群马达5，后群马达5带动镜头后群4调整，直至调焦画面中心区域的对比度传递函数值≥a0；若若调焦画面四个角落的对比度传递函数值≥a0，并且调焦画面中心区域的对比度传递函数值≥a0，则光机1安装聚焦合格。聚焦马达包括前群马达2和后群马达5。其中，特定值a0为光机1对比度传递函数值的合格标准。
步骤3)光照度均匀性校正包括如下步骤：
Ⅰ、将光照度均匀性校正画面(均匀分成5行10列，共50个格子)按照行列分成若干格子，光传感器8置于各个格子的上方，光传感器8测量输出光照度，控制模块9输出光照度读取指令以取得正确的光传感器8读取值，输出光照度与特定值b0比较；
Ⅱ、若光照度＞特定值b0，则增加该区域对应的灰度值，即减小输出光照度，使得最终使得每个格子的光照度均匀性测量值误差小于5％。即(最大值-最小值)/最大值＜5％。特定值b0为光机1光照度的合格标准。
步骤4)投影畸形校正包括如下步骤：
ⅰ、控制模块9通过HDMI高清线输入第一层影像，即输出标准校正块切片数据给光机1，开启UV LED(紫外发光二极管)开始固化，光机1逐层投射校正块切片数据至成型平台7，逐层成型校正块；
ⅱ、测量投影的校正块前后左右四个方向尺寸，若校正块前后尺寸不一致，调节光机安装及调节装置6使得投影的校正块前后尺寸一致；若校正块左右尺寸不一致，调节光机安装及调节装置6使得投影的校正块左右尺寸一致。
其中，如图7所示，标准校正块切片数据为标准60×120标准块切片文件，如：前后尺寸不一致，调节第一螺丝11，光机1相对成型平台7，绕Y轴旋转一定角度，使投影尺寸前后达到一致，如左大于右，调节第二螺丝12，光机1相对成型平台7，绕X轴旋转一定角度，使得投影的校正块左右尺寸一致，直至打印件对面尺寸均一致。
以上所述的具体实施例，对本发明的目的、技术方案和有益效果进行了进一步详细说明，所应理解的是，以上所述仅为本发明的具体实施例而已，并不用于限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (5)

  1. 一种用于DLP3D打印的智能校正控制方法，其特征在于：方法包括如下步骤：
    1)投影尺寸校正：控制模块(9)输出全幅画面信号给光机(1)，光机(1)投射全幅画面信号至成型平台(7)，通过对投影尺寸的检查，进行光机(1)安装高度的调校；
    步骤1)投影尺寸校正的具体步骤为：
    A、测量成型平台(7)上的投影全幅画面尺寸，包括X方向和Y方向的测量值；
    B、判断测量值和光机(1)预定全幅画面尺寸大小，如测量值比光机(1)预定全幅画面尺寸大，调节光机安装及调节装置(6)上移，使光机(1)和成型平台(7)距离减小，从而使光机(1)投射全幅画面尺寸减小；如测量值比光机(1)预定全幅画面尺寸小，调节光机安装及调节装置(6)下移，使光机(1)和成型平台(7)距离增大，从而使光机(1)投射全幅画面尺寸增大；
    C、再次重复步骤B，直至光机(1)投射全幅画面尺寸与预定全幅画面尺寸相符；
    2)投影聚焦校正：控制模块(9)输出调焦画面信号给光机(1)，光机(1)投射调焦画面信号至成型平台(7)，通过拍摄投影的调焦画面，进行光机(1)安装聚焦的确认；
    步骤2)投影聚焦校正包括如下步骤：
    a、数字摄像头(10)通过拍摄投影的调焦画面，判定投影的调焦画面四个角落以及中心区域的对比度传递函数值；
    b、若调焦画面四个角落的对比度传递函数值＜a0，控制模块(9)输出信号给后群马达(5)，后群马达(5)带动镜头后群(4)调整，直至调焦画面四个角落的对比度传递函数值≥a0；若调焦画面中心区域的对比度传递函数值＜a0，控制模块(9)输出信号给前群马达(2)，前群马达(2)带动镜头前群(3)调整，直至调焦画面中心区域的对比度传递函数值≥a0；若调焦画面四个角落的对比度传递函数值≥a0，并且调焦画面中心区域的对比度传递函数值≥a0，则光机(1)安装聚焦合格；
    3)光照度均匀性校正：控制模块(9)输出全白满幅画面信号给光机(1)，光机(1)投射光照度均匀性校正画面至成型平台(7)，通过测量光照度均匀性校正画面各个校正区域的光照度，从而进行光机(1)输出光照度均匀性校正；
    步骤3)光照度均匀性校正包括如下步骤：
    Ⅰ、将光照度均匀性校正画面按照行列分成若干格子，光传感器(8)置于各个格子的上方，光传感器(8)测量输出光照度，输出光照度与特定值b0比较；
    Ⅱ、若光照度＞特定值b0，则增加该格子区域对应的灰度值，最终使得每个格子的光照度均匀性测量值误差小于5％；
    4)投影畸形校正：控制模块(9)导入校正块切片数据，开启打印，控制模块(9)输出校正块切片数据给光机(1)，光机(1)逐层投射校正块切片数据至成型平台(7)，逐层成型校正块，测量校正块尺寸，进行光机(1)投影畸形校正；
    步骤4)投影畸形校正包括如下步骤：
    ⅰ、控制模块(9)输出标准校正块切片数据给光机(1)，开启UV LED开始固化，光机(1)逐层投射校正块切片数据至成型平台(7)，逐层成型校正块；
    ⅱ、测量投影的校正块前后左右四个方向尺寸，若校正块前后尺寸不一致，调节光机安装及调节装置(6)使得投影的校正块前后尺寸一致；若校正块左右尺寸不一致，调节光机安装及调节装置(6)使得投影的校正块左右尺寸一致。
  2. 根据权利要求1所述的一种用于DLP3D打印的智能校正控制方法，其特征在于：用于DLP3D打印的智能校正控制方法还包括，光机(1)输出光功率校正：控制模块(9)输出全白满幅画面信号给光机(1)，光机(1)投射全白满幅画面信号至成型平台(7)，通过采集光机(1)输出光功率进行光机(1)输出光功率校正。
  3. 根据权利要求2所述的一种用于DLP3D打印的智能校正控制方法，其特征在于：在步骤1)之前需要变更解析度；光机(1)与控制模块(9)通过HDMI高清线相连，控制模块(9)变更HDMI高清线的解析度从而与光机(1)初始解析度相匹配，使得光机(1)能够识别控制模块(9)输入的影像信号。
  4. 根据权利要求3所述的一种用于DLP3D打印的智能校正控制方法，其特征在于：光机(1)输出光功率校正时，光机(1)输出光功率通过光传感器(8)采集，光机(1)输出光功率校正通过调整LED的亮度来完成。
  5. 根据权利要求4所述的一种用于DLP3D打印的智能校正控制方法，其特征在于：LED的亮度＝1000×(LED的电流值)/30.0。
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