Today, Zmotion brings one Vision Correction Scan Precision Solution based one our Zmotion open laser scan motion controller ZMC408SCAN-V22.
Before that, let’s see current application market situation.
Laser Scan Control System extremely suits to high-speed and high-precision applications due to small inertia, low load, and rapid respond speed, for example, laser marking, welding, 3D printing, precision cutting, etc.
Laser Scan Control System mainly includes "laser scan control" and "graphic correction" , that is, it uses these two technical aspects to make the laser guidance be precise while processing. Specifically, it changes the laser direction by offsetting the lens at a high-speed, and makes the laser dynamically focus on any position on the site, then it will process according to preset trajectory, in this way, high-precision laser processing can be realized.
However, in the real production process, it may appear some fixed non-linear errors in the scanning field caused by many factors, like, optical, physical properties while laser scan is scanning, then the processing graphics become distortion, the quality is influenced. That is, the enterprise encounters a lot of problems, such as, high defective rate, high rework costs. Therefore, scan correction must be added.
For traditional scanning scan correction, generally it uses Box coefficient correction or multi-point correction, which means it needs labor to measure and record data, then compares theorical data with actual measured data.
As we all know, the request on high laser processing precision is increased, which means the distance between scanning points and the number of points to be measured are increased correspondingly. Then, it needs multiple superposition and measurement in the process of correction, causing low scan correction efficiency and low precision. In such complex and time-consuming correction, it is hard to meet application requirements of high-speed and high-precision in the market of laser.
According to this kind of situation in the traditional laser solution, Zmotion develops one high-speed & high-precision scan vision correction solution on the basis of laser scan motion controller. It can enhance the precision of scan laser processing system through correction compensation by machine vision.
Then, after correction compensation, motion control platform matches with CCD image acquisition coordinates, it can automatically positioning and acquire, which means more data can be marked. In addition, it can generate high-precision correction file rapidly through Zmotion multi-point scan correction deviation algorithm, those fixed deviations can be corrected by adjusting scan's angle. In this way, correction precision and efficiency are improved effectively.
Next, see more details.
1. High-Precision Scan Vision Correction Solution
Laser Scan System Processing
--Problems in Market Scan Correction Solution--
A. big errors and low efficiency caused by labor measurement.
B. high-precision two-dimensional measuring instrument is with high cost and complex operations.
C. hard to integrate with the software, and it doesn't support secondary development.
--Zmotion Scan Correction Solution--
(1) Zmotion Vision Correction Software
A. Operation Process
B. Test & Comparison of Correction Result
Before Scan Correction
After Scan Correction
It can be seen that the error values of points that are not corrected are bigger than that are corrected. Before correction , the error value is about ±0.5mm. After correction , obviously the error value is controlled in ±0.005mm.
Therefore, the processing precision is improved extremely by Zmotion laser vision correction solution based on laser scan motion controller.
(2) Solution Core Technology Advantages
A. support platform pitch compensation, and support two-dimensional compensation algorithm, precision can be enhanced.
B. automatically correct data, correction efficiency and precision are improved.
C. the software interfaces are with open API interfaces, then it is convenient to quick develop, integrate, and customize.
D. It integrates laser control, scan control, motion control, with machine vision, then accelerates software development.
(3) Solution Hardware Configuration
Product Type | Product Model | Manufacture | Number |
Machine Vision Motion Controller | Zmotion | 1 | |
Open Laser Scan Motion Controller | Zmotion | 1 | |
Motion Control Real-Time Kernel | Zmotion | 1 | |
Industrial Camera | 500W pixel | - | 1 |
Lens | 35mm | 1 | |
Light source | Circle type light source | - | 1 |
Light Source Controller | - | - | 1 |
Fiber Laser | - | - | 1 |
SCAN XY2-100 | - | - | 1 |
EtherCAT Servo Drives | - | - | 3 |
(4) What You can Get
A. the correction process is simplified, and the correction time is shortened 30%, then production efficiency is promoted a lot.
B. this is the automatic process, labor and time costs are reduced a lot.
C. there is one uniform API function interface, which can be compatible with all kinds of PC high-advanced languages, then it can simplify processes of engineer system integration and application development.
D. there is one embedded system in motion controller and laser technology controller that achieves real-time interaction. Through this, it reduces the requirement on PC interaction operation, then system respond speed and operation speed can be improved, specifically, the precision can be up to um level. More specifically, processing efficiency and precision can be improved above 10%, then defective rate is reduced.
2. Open Laser Scan Motion Controller ZMC408SCAN-V22
ZMC408SCAN-V22 is one standalone laser scan motion controller, which integrates laser control, scan control, and bus axis / pulse axis control. It can help you achieve high-precision and high-speed EtherCAT motion control + laser scan solution.
6-64 axes motion control (pulse + EtherCAT)
there are 2 laser scan interfaces with feedback, and 2 laser power specified interfaces (1 LASER & 1 FIBER)
support 1D / 2D / 3D PSO function, which can do vision fly-shooting, precision dispensing, and laser energy control
laser scan control and motion control are merged with together, then it can flexibly build laser processing system with multi-axis linkage method or other methods.
support multi-dimensional position synchronization output PSO -- there are 24 general inputs and 20 general outputs on the board, among them, 4 inputs support high-speed color code latching, 4 outputs support PSO, and 8 outputs support PWM.
Except “Vision Scan Correction” solution based on ZMC408SCAN-V22 open laser scan controller, there are wide application. Before, Zmotion also talked about “Power Battery Module Welding” solution by ZMC408SCAN-V22.
Former Solution Articles:
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Zmotion Motion Control Lithium Welding Application: High & Soft SS Curve