激光三维加工控制系统研究
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摘要
传统三维加工技术通常使用光学扫描系统(比如振镜、F-θ透镜)配合Z轴机械导轨实现三维扫描,也可以通过使用三个方向机械导轨来实现三维扫描,机械导轨的特点是可以提供一个方向任意大小的扫描范围。但是,随着产品小型化的发展趋势以及对加工速度要求越来越高,这种技术已经无法满足未来的生产需求。针对这种情况,设计了一种涉及光学、机械学、电子学、计算机控制等多个学科的激光三维加工控制系统,这是一种新型的三维加工技术,使用计算机绘制三维加工图形,然后通过自主开发的三维控制软件来控制激光束聚焦到被加工工件表面并进行三维扫描,从而完成对工件的三维加工。
本课题在激光加工过程的物理学基础上,对激光三维加工控制系统进行了研究,系统适用于工件尺寸小于170*170mm2、速度要求在10m/s以上的应用场合。论文首先从传统激光三维技术入手,介绍当前技术的现状和不足,分析了激光与物质相互作用的过程,对常用的激光扫描方法进行分析。然后引入动态聚焦概念,选出最适合的激光器和光路结构,并对比传统导轨技术指出使用光学三维扫描技术的优势。然后详细研究了振镜系统的原理、动态聚焦镜的原理以及如何通过PCI总线结合DSP控制激光束的开关和移动。
论文提出了一种三维图形填充算法,通过对三维轮廓图形进行线条填充,实现了对工件三维表面的加工。设计了激光三维加工控制软件,实现了三维图形文件读取与显示、图形填充、参数设置、激光控制等功能。此外,基于OpenGL技术为控制软件增加了三维显示的功能,方便工件定位。
在实际使用设备的过程中,对设备进行了改善:增加了隔离装置,将激光加工区域和操作区域隔离,保证操作人员安全;增加了除尘装置,降低了加工中烟雾对光学镜头的污染;增加了安全装置,确保机箱盖被打开时激光处于关断状态;增加旋转工作台,大幅提高了工作效率。
最后通过实验数据验证了激光三维加工控制系统的可行性、稳定性和精度,达到设计要求,同时找到了针对不同材料最适合加工的参数。提出了不足之处,以及需要进一步解决的技术问题。
Traditional 3D laser processing technology usually uses mechanism guide rail to produce 3D scanning, and it has advantage over the range of processing. But it costs time and is also complicated. As miniaturization is the development trend of equipments, mechanism guide rail can’t meet the needs of production process . To solve this problem, we designed a digital controlled laser 3D processing system which involves optics, mechanics, electronics and computer science. This is a new kind of 3D laser processing technology. The system process the surface of the material by moving the beams of laser based on the design of the 3D figures by control of computer. Also, it can crease, perforate, mark and encrypt on the pack surface by controlling the laser power and speed.
The purpose of this paper is to research the processing of digital controlled 3D laser system base on the analysis of the laser processing physics theory.
The paper begins with traditional 3D laser processing technology, introduces the status quo of current 3D laser processing technology and its shortage,then followed by the concept of laser process, compares common laser scanning methods, chooses the most compatible laser and optical circuit. After studying the process of laser and substance working on each other,the theory of high speed galvanometer scanning system, the dynamic focus system, the laser power digital controlled circuit and how to control the laser moving by PCI bus and DSP are expounded.
The paper raises the point of 3D graph padding arithmetic which has been implemented in the 3D laser controlling software developed by ourselves. The 3D movement of laser beam is under the control of this software. 3D dynamic display of the 3D graph of processing workpiece has been realized in this software based on OpenGL API functions, which makes easier for observing and positioning of the workpiece.
We make some improvement during the use of digital controlled 3D laser system. For example, the safety glass separates the processing area from the operating area, which improves the laser equipment’s safety; the dusting machine clean up dust to protect lens that comes from the work piece while processing; the power will go down while opening the cover of laser equipment to protect operator and system; the rotary worktable realizes processing one work piece while mounting another, thus improves the efficiency of system at least by 50%.
At last we validate the system stability and precision by a series of experiments. The result is accord with the design. Some suitable processing parameters, something that can be improved, some technology problems to be solved are all mentioned here.
本课题在激光加工过程的物理学基础上,对激光三维加工控制系统进行了研究,系统适用于工件尺寸小于170*170mm2、速度要求在10m/s以上的应用场合。论文首先从传统激光三维技术入手,介绍当前技术的现状和不足,分析了激光与物质相互作用的过程,对常用的激光扫描方法进行分析。然后引入动态聚焦概念,选出最适合的激光器和光路结构,并对比传统导轨技术指出使用光学三维扫描技术的优势。然后详细研究了振镜系统的原理、动态聚焦镜的原理以及如何通过PCI总线结合DSP控制激光束的开关和移动。
论文提出了一种三维图形填充算法,通过对三维轮廓图形进行线条填充,实现了对工件三维表面的加工。设计了激光三维加工控制软件,实现了三维图形文件读取与显示、图形填充、参数设置、激光控制等功能。此外,基于OpenGL技术为控制软件增加了三维显示的功能,方便工件定位。
在实际使用设备的过程中,对设备进行了改善:增加了隔离装置,将激光加工区域和操作区域隔离,保证操作人员安全;增加了除尘装置,降低了加工中烟雾对光学镜头的污染;增加了安全装置,确保机箱盖被打开时激光处于关断状态;增加旋转工作台,大幅提高了工作效率。
最后通过实验数据验证了激光三维加工控制系统的可行性、稳定性和精度,达到设计要求,同时找到了针对不同材料最适合加工的参数。提出了不足之处,以及需要进一步解决的技术问题。
Traditional 3D laser processing technology usually uses mechanism guide rail to produce 3D scanning, and it has advantage over the range of processing. But it costs time and is also complicated. As miniaturization is the development trend of equipments, mechanism guide rail can’t meet the needs of production process . To solve this problem, we designed a digital controlled laser 3D processing system which involves optics, mechanics, electronics and computer science. This is a new kind of 3D laser processing technology. The system process the surface of the material by moving the beams of laser based on the design of the 3D figures by control of computer. Also, it can crease, perforate, mark and encrypt on the pack surface by controlling the laser power and speed.
The purpose of this paper is to research the processing of digital controlled 3D laser system base on the analysis of the laser processing physics theory.
The paper begins with traditional 3D laser processing technology, introduces the status quo of current 3D laser processing technology and its shortage,then followed by the concept of laser process, compares common laser scanning methods, chooses the most compatible laser and optical circuit. After studying the process of laser and substance working on each other,the theory of high speed galvanometer scanning system, the dynamic focus system, the laser power digital controlled circuit and how to control the laser moving by PCI bus and DSP are expounded.
The paper raises the point of 3D graph padding arithmetic which has been implemented in the 3D laser controlling software developed by ourselves. The 3D movement of laser beam is under the control of this software. 3D dynamic display of the 3D graph of processing workpiece has been realized in this software based on OpenGL API functions, which makes easier for observing and positioning of the workpiece.
We make some improvement during the use of digital controlled 3D laser system. For example, the safety glass separates the processing area from the operating area, which improves the laser equipment’s safety; the dusting machine clean up dust to protect lens that comes from the work piece while processing; the power will go down while opening the cover of laser equipment to protect operator and system; the rotary worktable realizes processing one work piece while mounting another, thus improves the efficiency of system at least by 50%.
At last we validate the system stability and precision by a series of experiments. The result is accord with the design. Some suitable processing parameters, something that can be improved, some technology problems to be solved are all mentioned here.
引文
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[18]李芳菲,张珂殊,龚强,无扫描三维成像激光雷达原理分析与成像仿真,科技导报,2009,27(8):60~64
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[21]郑启光,激光先进制造技术,武汉:华中科技大学出版社,2002
[22]www.scanlab.de/
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[28]石顺祥等,物理光学与应用光学,西安:西安电子科技大学出版社,2000
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