A multi-wire saw production method for camera color filter

Abstract

This invention discloses a multi-wire cutting production method for camera color filters, belonging to the field of color filter processing technology. This process achieves efficient color filter cutting through three core steps: precise compensation data testing, hexagonal single-sided contour cutting, and hexagonal cutting. The invention employs a hexagonal cutting layout, increasing material utilization by 5.5% while reducing machining allowance in the rounding process, thus improving production efficiency, all while maintaining the same output quantity. The application of translational worktable control compensation technology ensures the accuracy of the cutting path, solving the problems of low material utilization and excessive machining allowance in traditional cutting processes, making it suitable for the large-scale production of camera color filters.

Description

Technical Field

[0001] This invention relates to a cutting control method, and more specifically, to a multi-wire cutting production method for camera color filters. Background Technology

[0002] A camera typically consists of several components, including a mount, lens, color filters, CIS (image sensor), and ISP (image signal processing) chip. Among these, color filters (often called light filters) are key optical components that ensure accurate color reproduction and enable rich functionality. Despite their small size, their role is crucial. Color filters act like "gatekeepers of light," filtering and selecting incident light. The main types include: infrared cut-off filters (acting as "gatekeepers" of color), narrowband filters (acting as "security inspectors" for 3D vision), and Bayer color filter arrays (forming the "mosaic" of color imaging). The core technology of color filters lies in the coating process. Currently, advanced multi-layer nano-coating technology can achieve visible light transmittance exceeding 95% and more precisely control the spectral cut-off range.

[0003] In color filter production, the coating process accounts for the highest cost; therefore, improving coating utilization is crucial for controlling production costs. (Refer to...) Figure 1 As shown, in the current production process, there is a large processing allowance on the outer periphery of the color filter, resulting in a significant waste of area.

[0004] Therefore, a new technical solution is needed to address the filter cutting and production process. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a multi-wire cutting production method for camera color filters.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A multi-wire cutting production method for camera color filters includes the following steps:

[0008] Step S0: Precise compensation data test. According to the preset cutting path based on the cutting angle, the compensation amount is obtained based on the actual cutting path and the preset cutting path.

[0009] Step S1: Cut the hexagonal outline on one side to form multiple continuous regular hexagonal structures;

[0010] Step S2: Hexagonal cutting, cutting the continuous regular hexagonal structure into regular hexagonal blocks.

[0011] The present invention is further configured such that step S0 includes the following steps:

[0012] Step S0-1: First round of uncompensated cutting and deviation data acquisition;

[0013] Step S0-2: Piecewise fitting of the basic compensation function in the first round;

[0014] Step S0-3: Multi-round iterative calibration;

[0015] Step S0-4: Iteration termination judgment.

[0016] The present invention is further configured such that, in step S0-1, the first round of uncompensated cutting and deviation data acquisition is performed:

[0017] According to the process requirements, the cutting is carried out at a preset angle, and the translation and lifting movements are controlled in a coordinated manner to perform inclined cutting.

[0018] After the cutting is completed, measure the actual cutting path and calculate the difference in translation position between the actual cutting path and the preset cutting path;

[0019] Step S0-2, Piecewise fitting of the first round of basic compensation function:

[0020] Based on the difference in translation position, the translation compensation amount at each position during the lifting and lowering motion is obtained, and the first translation compensation function x=f1(y) is obtained.

[0021] The present invention is further configured such that, in step S0-3, multi-round iterative calibration is performed:

[0022] According to the process requirements, the cutting is carried out at a preset angle, and the translation and lifting movements are linked and controlled to perform tilted cutting; during the cutting process, position compensation is performed according to a translation compensation function.

[0023] After the cutting is completed, measure the actual cutting path and calculate the difference in translation position between the actual cutting path and the preset cutting path;

[0024] Based on the difference in translation position, the translation compensation amount at each position during the lifting and lowering motion is obtained, and the translation compensation function x=fn(y) for the nth time is obtained.

[0025] Step S0-4, Iteration termination judgment:

[0026] The translation compensation function x=fn(y) for the nth time is used to measure the maximum horizontal deviation |Δxmax| between the actual cutting path and the preset path;

[0027] If |Δxmax| ≤ the deviation threshold during three consecutive iterations of calibration, the iteration terminates, and the average value of the three obtained translation compensation functions is taken to obtain the translation compensation function x=f(y) obtained in the iteration; otherwise, step S0-3 is repeated to enter the next cycle, n=n+1.

[0028] The present invention is further configured such that step S0 includes the following steps: step S0-5, compensation function smoothing optimization, performing three-point moving average smoothing on the translation compensation function x=f(y) obtained by iteration, taking the average value of the compensation of three adjacent sampling points, and eliminating the fluctuation of sampling points.

[0029] The present invention is further configured such that, during the cutting process in step S1, the cutting material is located above the cutting line, and the cutting is performed from top to bottom.

[0030] The present invention is further configured such that step S1 includes the following steps:

[0031] Step S1-1: Before starting the cutting, pre-embed the cutting line;

[0032] Step S1-2: Cut from the starting point, and cut along the preset angle until the first inflection point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount;

[0033] Step S1-3: Cut from the first inflection point, and cut along a straight line until the second inflection point;

[0034] Steps S1-4: Cut from the second inflection point, and cut along the preset angle until the third inflection point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount;

[0035] Steps S1-5: Cut from the third inflection point, and cut along a straight line until the fourth inflection point;

[0036] Step S1-6: Repeat steps S1-2 to S1-5 until the single-sided contour line cutting is completed; use the fourth inflection point of the previous cycle as the cutting starting point of the next cycle.

[0037] Steps S1-7: Exit the cutting line along the cutting path.

[0038] The present invention is further configured such that, during step S1, a delay is made at each inflection point, and cutting continues after the cutting line stabilizes.

[0039] The present invention is further configured such that step S2 includes the following steps:

[0040] Step S2-1: Cut from the starting point, the cutting line cuts along the preset angle to the first cutting point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount;

[0041] Step S2-2: Cut from the first cutting point, and the cutting line extends along a straight line to the second cutting point;

[0042] Step S2-3: Cut from the second cutting point, and cut along the preset angle to the third cutting point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount;

[0043] Step S2-4: Cut from the third cutting point, with the cutting line running along a straight line to the fourth cutting point;

[0044] Step S2-5: Repeat steps S2-1 to S2-4 until the entire block is cut; use the fourth cutting point of the previous cycle as the starting point for the next cycle.

[0045] The present invention is further configured such that, during step S2, a delay is made at each cutting point, and cutting continues after the cutting line stabilizes.

[0046] In summary, the present invention has the following beneficial effects:

[0047] Using a multi-wire cutting machine to cut hexagons improves material utilization and reduces workpiece machining allowance compared to the traditional square cutting process. Moreover, the cut results in a regular hexagonal cross-section, which significantly improves the efficiency of the rounding process compared to the traditional square structure.

[0048] By compensating for the cutting offset during the inclined cutting process and performing multiple iterative compensation operations, an accurate cutting path can be obtained, which can meet the workpiece's requirements for cutting precision and thus effectively ensure the forming quality of the color filter. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the cutting structure of a color filter workpiece in the prior art. The left side shows the overall cutting distribution of the workpiece, and the right side shows a single workpiece after cutting.

[0050] Figure 2 This is a schematic diagram of the cutting structure of the color filter workpiece in this embodiment. The left side shows the overall cutting distribution of the workpiece, and the right side shows a single workpiece after cutting.

[0051] Figure 3 This is a schematic diagram showing the comparison between the actual cutting path and the preset cutting path in this embodiment;

[0052] Figure 4 This is a schematic diagram of the hexagonal single-sided contour line cutting structure in step S1 of this embodiment;

[0053] Figure 5 This is a schematic diagram of the overall structure of the hexagonal outline cutting in step S1 of this embodiment;

[0054] Figure 6 This is a schematic diagram of the hexagonal cutting structure in step S2 of this embodiment;

[0055] Figure 7This is a schematic diagram of the overall structure of the hexagonal cutting in step S1 of this embodiment. Detailed Implementation

[0056] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0057] This embodiment discloses a multi-wire cutting production method for camera color filters, referring to... Figures 2-7 As shown, the steps include:

[0058] Step S0: Precise compensation data test. According to the preset cutting path based on the cutting angle, the compensation amount is obtained based on the actual cutting path and the preset cutting path.

[0059] Step S1: Cut the hexagonal outline on one side to form multiple continuous regular hexagonal structures;

[0060] Step S2: Hexagonal cutting, cutting the continuous regular hexagonal structure into regular hexagonal blocks.

[0061] Specifically, step S0 includes the following steps: step S0-1 first round of uncompensated cutting and deviation data acquisition, step S0-2 first round of basic compensation function piecewise fitting, step S0-3 multi-round iterative calibration, and step S0-4: iterative termination judgment.

[0062] Step S0-1: First round of uncompensated cutting and deviation data acquisition

[0063] According to the process requirements, i.e. the same parameters as the formal cutting, the cutting is carried out according to the preset tilt angle, and the cutting angle is 30° and 150° according to the regular hexagonal structure; during the cutting process, the translation and lifting movements are linked and controlled to carry out the tilt cutting.

[0064] After the cutting is completed, laser ranging is used to measure and obtain the actual cutting path, and the difference in translation position between the actual cutting path and the preset cutting path is calculated.

[0065] During the cutting process, due to the flexibility of the cutting line, the actual cutting path is curved rather than straight, which can be divided into a curvature increase zone and a curvature stability zone. In the initial cutting stage, the pressure on the cutting line gradually increases, and its curvature changes in the early stage of the cutting, which corresponds to the curvature increase zone during the cutting process. After the cutting state stabilizes, the cutting inclination gradually stabilizes. When the cutting depth reaches a certain level, the curvature of the cutting line tends to stabilize, and its arc is basically parallel to the 30° direction and within a reasonable range.

[0066] Step S0-2, Piecewise Fitting of the First Round of Basic Compensation Function

[0067] During the cutting process, it is necessary to compensate for the differences in translation position. Based on the differences in translation position, the translation compensation amount corresponding to each position during the lifting and lowering motion is matched; based on the correspondence between the lifting and lowering position (y) and the translation compensation amount (x), the first translation compensation function x=f1(y) is fitted.

[0068] Step S0-3, multi-round iterative calibration

[0069] The tilting cut is performed again according to the preset tilt angle of the process. The translation mechanism and the lifting mechanism are linked and controlled. During the cutting process, the first translation compensation function obtained in step S0-2 is substituted to perform real-time position compensation.

[0070] After the cutting is completed, measure the actual cutting path and compare it with the preset cutting path to calculate the difference in translation position;

[0071] Based on the new translation position difference, the translation compensation amount of each position of the lifting and lowering motion is matched, and the nth translation compensation function x=fn(y) is obtained by fitting; n is the iteration number, initially n=2, and n increments by 1 in each cycle.

[0072] Step S0-4, Iteration termination judgment

[0073] Based on the nth translation compensation function x=fn(y), the maximum horizontal deviation |Δxmax| between the actual cutting path and the preset path is measured and calculated;

[0074] The termination rule is as follows: if the maximum horizontal deviation in each of the three consecutive iterations of calibration satisfies |Δxmax| ≤ deviation threshold, then the iteration terminates; if the condition is not met, then S0-3 is repeated to enter the next iteration of calibration, n=n+1.

[0075] After the iteration terminates, the average value of the translation compensation functions that meet the criteria three times consecutively is taken to obtain the final translation compensation function x=f(y) of the iteration.

[0076] Steps S0-5: Smooth optimization of the compensation function

[0077] The translation compensation function x=f(y) obtained through iteration is smoothed by a three-point moving average. The average value of the translation compensation corresponding to three adjacent sampling points of the lifting and lowering motion position is taken to eliminate the random fluctuations of the sampling points, ensure the continuity and smoothness of the function, and obtain the final accurate compensation function that can be directly used for subsequent cutting processes.

[0078] In step S1, the hexagonal single-sided contour line is cut to form multiple continuous regular hexagonal structures. During the cutting process, the cutting material is located above the cutting line and cut from top to bottom, so that the hexagonal cutting material can fall off naturally after the cutting is completed.

[0079] Reference Figure 4 , Figure 5 As shown, step S1 includes the following steps:

[0080] Step S1-1: Before starting the cutting, pre-cut the cutting line to avoid the cutting line slipping due to direct cutting in the initial cutting stage;

[0081] Step S1-2: Cut from the starting point, and cut along the preset angle until the first inflection point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount;

[0082] Starting from the cutting point 1-0, cut in a 45° direction towards the upper right corner until reaching the cutting point 1-1 (the first inflection point). Calculate the path length (i.e., the straight line length from the starting point 1-0 to the cutting point 1-1) based on the required cutting circle diameter Φ. During this process, substitute the compensation function x=f(y) obtained in step S0-4 to compensate for the position value of X, making the actual cutting path fit the preset cutting path.

[0083] Steps S1-3: Delay and wait at each inflection point until the cutting line stabilizes before continuing to cut, ensuring the point is accurately positioned to facilitate subsequent hexagonal truncation and normal falling.

[0084] Cut along a vertical line from cutting point 1-1 (first inflection point) to cutting point 1-2 (second inflection point). After reaching cutting point 1-2 (second inflection point), perform a delayed cut to reduce the positional offset caused by the flexibility of the cutting line.

[0085] Steps S1-4: Delay and wait at each inflection point until the cutting line stabilizes before continuing to cut, ensuring the accuracy of the point's position;

[0086] Starting from cutting point 1-2 (the second inflection point), cut in a 150° direction towards the upper left corner, until reaching cutting point 1-3 (the third inflection point). The compensation data is based on the compensation function x=f(y) obtained in step S0-4.

[0087] Steps S1-5: Delay and wait at each inflection point until the cutting line stabilizes before continuing to cut, ensuring the accuracy of the point's position;

[0088] Cut along the vertical line from cutting point 1-3 (the third inflection point) to cutting point 1-4 (the fourth inflection point). After reaching cutting point 1-4 (the fourth inflection point), perform a delayed cut to reduce the positional offset caused by the flexibility of the cutting line.

[0089] Step S1-6: Repeat steps S1-2 to S1-5 until the single-sided contour line cutting is completed; use the cutting point 1-4 (fourth inflection point) of the previous cycle as the cutting point 1-1 (cutting start point) of the next cycle.

[0090] Steps S1-7: Exit the cutting line along the cutting path, maintaining the cutting line speed at 3m / min (typical value) during the exit process to reduce the possibility of the line getting stuck.

[0091] Reference Figure 6 , Figure 7 As shown, in this embodiment, step S2 includes the following steps:

[0092] Step S2-1: Start cutting from the starting point 2-0 (cutting starting point), and cut along the preset angle to the cutting point 2-1 (first cutting point); during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount, and the compensation adjustment data refers to the compensation function x = f(y) mentioned above;

[0093] Step S2-2: Cut from cutting point 2-1 (first cutting point), and the cutting line is straight to cutting point 2-2 (second cutting point); feed the tool in a vertical direction. The cutting in this direction has been completed. The feed speed can be increased to quickly complete the path. When reaching cutting point 2-2 (second cutting point), a delay is made to wait so that the cutting line can maintain a more accurate state.

[0094] Step S2-3: Start cutting from cutting point 2-2 (second cutting point), and cut along the preset angle to cutting point 2-3 (third cutting point); during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount, and the compensation adjustment data refers to the compensation function x = f(y) mentioned above;

[0095] Step S2-4: Cut from cutting point 2-3 (third cutting point), and the cutting line is straight to cutting point 2-4 (fourth cutting point); feed the tool in the vertical direction. The cutting in this direction has been completed. The feed speed can be increased to quickly complete the path. When reaching cutting point 2-4 (fourth cutting point), delay and wait so that the cutting line can maintain a more accurate state.

[0096] Step S2-5: Repeat steps S2-1 to S2-4 until the entire block is cut; use the fourth cutting point of the previous cycle as the starting point for the next cycle; cut the entire block into a structure with a regular hexagonal cross-section.

[0097] In existing technologies, multi-wire cutting machines, with their advantages of high precision and low wear, have become an important method for processing color filters. Current conventional cutting processes involve stacking coated color filters, first cutting them into strips, then re-bonding them, and further cutting them into square cylindrical shapes, as shown in the reference... Figure 1 As shown (the right side is a magnified view of a portion, and the shaded area represents the machining allowance). In the illustrated example, 100 finished products of 10×10 can be made from a 100×100 coating area.

[0098] In the scheme of this embodiment, refer to Figure 2 As shown, the cut hexagonal structure, with a coating area of ​​105×90, can produce 100 finished products of 10×10. On the same basis, the material utilization rate can be increased by approximately 5.5%, thereby effectively improving the production efficiency of the enterprise; moreover, in this embodiment, the significantly reduced allowance on the outer periphery of the communion filter workpiece can also reduce the amount of processing in the subsequent rounding process, further improving production efficiency.

[0099] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A multi-wire cutting production method for camera color filters, characterized in that, Including the following steps: Step S0: Precise compensation data test. According to the preset cutting path based on the cutting angle, the compensation amount is obtained based on the actual cutting path and the preset cutting path. Step S1: Cut the hexagonal outline on one side to form multiple continuous regular hexagonal structures; Step S2: Hexagonal cutting, cutting the continuous regular hexagonal structure into regular hexagonal blocks; Step S0 includes the following steps: Step S0-1, First round of uncompensated cutting and deviation data acquisition: According to the process requirements, the cutting is carried out at a preset angle, and the translation and lifting movements are controlled in a coordinated manner to perform inclined cutting. After the cutting is completed, measure the actual cutting path and calculate the difference in translation position between the actual cutting path and the preset cutting path; Step S0-2, Piecewise fitting of the first round of basic compensation function: Based on the difference in translation position, the translation compensation amount at each position during the lifting and lowering motion is obtained, and the first translation compensation function x=f1(y) is obtained. Step S0-3, multi-round iterative calibration: According to the process requirements, the cutting is carried out at a preset angle, and the translation and lifting movements are linked and controlled to perform tilted cutting; during the cutting process, position compensation is performed according to a translation compensation function. After the cutting is completed, measure the actual cutting path and calculate the difference in translation position between the actual cutting path and the preset cutting path; Based on the difference in translation position, the translation compensation amount at each position during the lifting and lowering motion is obtained, and the translation compensation function x=fn(y) for the nth time is obtained. Step S0-4, Iteration termination judgment: The translation compensation function x=fn(y) for the nth time is used to measure the maximum horizontal deviation |Δxmax| between the actual cutting path and the preset path; If |Δxmax| ≤ the deviation threshold during three consecutive iterations of calibration, the iteration terminates, and the average value of the three obtained translation compensation functions is taken to obtain the translation compensation function x=f(y) obtained in the iteration; otherwise, step S0-3 is repeated to enter the next cycle, n=n+1.

2. The multi-wire cutting production method for camera color filters according to claim 1, characterized in that, Step S0 also includes the following steps: Step S0-5, Smoothing optimization of compensation function: Perform three-point moving average smoothing on the translation compensation function x=f(y) obtained by iteration, and take the average value of the compensation of three adjacent sampling points to eliminate the fluctuation of sampling points.

3. The multi-wire cutting production method for camera color filters according to claim 1, characterized in that, During the cutting process in step S1, the cutting material is located above the cutting line and is cut from top to bottom.

4. The multi-wire cutting production method for camera color filters according to claim 1, characterized in that, Step S1 includes the following steps: Step S1-1: Before starting the cutting, pre-embed the cutting line; Step S1-2: Cut from the starting point, and cut along the preset angle until the first inflection point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount; Step S1-3: Cut from the first inflection point, and cut along a straight line until the second inflection point; Steps S1-4: Cut from the second inflection point, and cut along the preset angle until the third inflection point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount; Steps S1-5: Cut from the third inflection point, and cut along a straight line until the fourth inflection point; Step S1-6: Repeat steps S1-2 to S1-5 until the single-sided contour line cutting is completed; use the fourth inflection point of the previous cycle as the cutting starting point of the next cycle. Steps S1-7: Exit the cutting line along the cutting path.

5. A multi-wire cutting production method for camera color filters according to claim 4, characterized in that, During step S1, a delay is made at each inflection point to wait for the cutting line to stabilize before continuing to cut.

6. The multi-wire cutting production method for camera color filters according to claim 1, characterized in that, Step S2 includes the following steps: Step S2-1: Cut from the starting point, the cutting line cuts along the preset angle to the first cutting point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount; Step S2-2: Cut from the first cutting point, and the cutting line extends along a straight line to the second cutting point; Step S2-3: Cut from the second cutting point, and cut along the preset angle to the third cutting point; during the cutting process, real-time compensation adjustment is performed according to the compensation function of the compensation amount; Step S2-4: Cut from the third cutting point, with the cutting line running along a straight line to the fourth cutting point; Step S2-5: Repeat steps S2-1 to S2-4 until the entire block is cut; use the fourth cutting point of the previous cycle as the starting point for the next cycle.

7. A multi-wire cutting production method for camera color filters according to claim 6, characterized in that, During step S2, a delay is made at each cutting point to wait for the cutting line to stabilize before continuing to cut.

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