Optical lens mold manufacturing method

Abstract

The application relates to an optical lens mold manufacturing method, which comprises the following steps: detecting the size parameters of a to-be-processed surface of a mold core; establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface; determining the center coordinates of each core hole based on the processing coordinate system and using preset design parameters; forming a plurality of core holes on the to-be-processed surface by using a fine processing device according to the center coordinates of each core hole; taking the center of the core hole as a centering reference, determining the coordinates of each column foot position corresponding to the core hole based on the centering reference; and forming a plurality of column foot positions on the to-be-processed surface by using the fine processing device according to the coordinates of each column foot position. By taking the center coordinates of each core hole as the centering reference, the error of the distance between the core hole and the column foot can be effectively reduced, the concentricity between the column foot position and the core hole is improved, the concentricity of the front mold and the rear mold is higher, the concentricity of the optical lens manufactured by the mold core is better, and the precision and the optical performance of the optical lens are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of optical lens manufacturing, in particular to an optical lens mold manufacturing method. BACKGROUND

[0002] The optical lens refers to a lens in a backlight module of a liquid crystal display screen. The optical lens is covered on an LED (light-emitting diode) lamp bead and is used to diffuse light emitted by the LED lamp bead to a liquid crystal, so as to make the liquid crystal emit light and display.

[0003] The precision of the optical lens affects the backlight effect of the backlight module. One of the factors affecting the precision of the optical lens is the center offset degree of the optical lens. The optical lens is produced by a mold, and the concentricity of the mold determines the center offset degree of the optical lens.

[0004] The existing optical lens mold includes a front mold and a rear mold. If the centers of the front mold and the rear mold (or the upper mold and the lower mold) cannot be aligned, the center of the produced optical lens will be offset, and the parameter requirements of the optical lens cannot be met. SUMMARY

[0005] Therefore, it is necessary to provide an optical lens mold manufacturing method.

[0006] An optical lens mold manufacturing method comprises the following steps:

[0007] providing a mold core;

[0008] coarsely processing the mold core to obtain a coarsely processed mold core;

[0009] installing the coarsely processed mold core on a fine processing device, and calibrating the flatness and perpendicularity of the mold core on the fine processing device;

[0010] detecting the size parameters of a to-be-processed surface of the mold core, establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface;

[0011] determining the center coordinates of each core hole based on the processing coordinate system and preset design parameters;

[0012] forming a plurality of core holes on the to-be-processed surface by using the fine processing device according to the center coordinates of each core hole;

[0013] taking the centers of the core holes as a reference, determining the coordinates of each column foot position corresponding to the core holes based on the reference;

[0014] forming a plurality of column foot positions on the to-be-processed surface by using the fine processing device according to the coordinates of each column foot position.

[0015] In one of the embodiments, the step of detecting the size parameters of the to-be-processed surface of the die core, and establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface comprises:

[0016] acquiring an image of the to-be-processed surface of the die core on the fine processing device by the image sensor to obtain a to-be-processed surface image;

[0017] performing a binaryzation processing on the to-be-processed surface image to obtain a binaryzation image of the to-be-processed surface;

[0018] extracting geometric features of the binaryzation image according to the structure of surface, line and point to obtain surface features, line features and point features of the to-be-processed surface;

[0019] reconstructing a feature image of the to-be-processed surface by using the surface features, the line features and the point features to obtain a geometric feature map;

[0020] detecting the size parameters of the to-be-processed surface of the die core according to the geometric feature map, and establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface.

[0021] In one of the embodiments, the step of detecting the size parameters of the to-be-processed surface of the die core according to the geometric feature map, and establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface comprises:

[0022] detecting the size parameters of the to-be-processed surface of the die core according to the geometric feature map;

[0023] detecting whether the size parameters meet a concentric precision condition;

[0024] when the size parameters do not meet the concentric precision condition, determining a geometric center of the to-be-processed surface according to the size parameters of the to-be-processed surface, and establishing a processing coordinate system of the to-be-processed surface with the geometric center of the to-be-processed surface as a coordinate origin.

[0025] In one of the embodiments, the step of detecting the size parameters of the to-be-processed surface of the die core according to the geometric feature map, and establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface comprises:

[0026] when the size parameters meet the concentric precision condition, determining an intersection point of two adjacent edges of the to-be-processed surface according to the size parameters of the to-be-processed surface, and establishing a processing coordinate system of the to-be-processed surface with the intersection point as a coordinate origin.

[0027] In one of the embodiments, the step of detecting the size parameters of the to-be-processed surface of the die core according to the geometric feature map, and establishing a processing coordinate system of the to-be-processed surface based on the size parameters of the to-be-processed surface comprises:

[0028] According to the size parameter of the surface to be machined, a test coordinate system is established with the intersection point of two adjacent edges of the surface to be machined as the coordinate origin;

[0029] Based on the test coordinate system, the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions are determined by using the preset design parameters;

[0030] According to the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions, the test center coordinates of the surface to be machined are calculated;

[0031] According to the size parameter of the surface to be machined, the geometric center coordinates of the surface to be machined are determined;

[0032] It is detected whether the deviation between the test center coordinates and the geometric center coordinates is less than a preset threshold value;

[0033] If the deviation between the test center coordinates and the geometric center coordinates is less than the preset threshold value, the size parameter meets the concentricity precision condition; if the deviation between the test center coordinates and the geometric center coordinates is greater than or equal to the preset threshold value, the size parameter does not meet the concentricity precision condition.

[0034] In one of the embodiments, before the step of performing binaryzation processing on the surface-to-be-machined image to obtain a binaryzation image of the surface to be machined, the method further comprises:

[0035] The surface-to-be-machined image is input into an image recognition model, and the noise region in the surface-to-be-machined image is identified by using the image recognition model, and noise identification is added to the noise region;

[0036] The step of performing binaryzation processing on the surface-to-be-machined image to obtain a binaryzation image of the surface to be machined comprises:

[0037] According to the noise identification, binaryzation processing is performed on the surface-to-be-machined image, and the noise region corresponding to the noise identification is removed to obtain a binaryzation image of the surface to be machined.

[0038] In one of the embodiments, the step of installing the rough-machined mold core on a finishing equipment and calibrating the flatness and perpendicularity of the mold core on the finishing equipment comprises:

[0039] The rough-machined mold core is installed on a finishing equipment, and the three-dimensional feature parameters of the mold core are measured by using a range finder;

[0040] According to the three-dimensional feature parameters, it is detected whether the flatness and perpendicularity of the mold core on the finishing equipment meet a preset flatness and a preset perpendicularity;

[0041] When the flatness and perpendicularity of the mold core on the finishing equipment do not meet preset flatness and preset perpendicularity, a mechanical arm is controlled to adjust the position and angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity, so as to calibrate the flatness and perpendicularity of the mold core on the finishing equipment.

[0042] When the flatness and perpendicularity of the mold core on the finishing equipment meet preset flatness and preset perpendicularity, a three-dimensional model of the mold core is constructed according to the three-dimensional feature parameters.

[0043] In one embodiment, the step of reconstructing the feature image of the surface to be machined by using the surface feature, the line feature and the point feature to obtain a geometric feature map comprises:

[0044] The three-dimensional model of the mold core is analyzed to obtain two-dimensional feature parameters of the surface to be machined;

[0045] The two-dimensional feature parameters are compared with the surface feature, the line feature and the point feature to establish a corresponding relationship between the two-dimensional feature parameters and the surface feature, the line feature and the point feature;

[0046] Based on the corresponding relationship between the two-dimensional feature parameters and the surface feature, the line feature and the point feature, the corresponding surface feature, line feature and point feature are constrained by using the two-dimensional feature parameters;

[0047] The feature image of the surface to be machined is reconstructed by using the surface feature, the line feature and the point feature to obtain a geometric feature map.

[0048] In one embodiment, the step of measuring the three-dimensional feature parameters of the mold core by using a range finder comprises:

[0049] A reference three-dimensional model is obtained, wherein the reference three-dimensional model records three-dimensional parameters of a standard mold core and records a measurement reference of a mold core;

[0050] The geometric parameters of at least one side edge of the mold core are measured by using a range finder;

[0051] A three-dimensional detection coordinate is constructed by using the geometric parameters of at least one side edge of the mold core;

[0052] The measurement reference is extracted from the reference three-dimensional model, and the measurement position and measurement angle of the range finder are determined based on the three-dimensional detection coordinate and the measurement reference;

[0053] The position and angle of the range finder are adjusted based on the measurement position and the measurement angle, and the three-dimensional feature parameters of the mold core are measured by using the range finder.

[0054] The step of detecting whether the flatness and perpendicularity of the mold core on the finishing equipment meet preset flatness and preset perpendicularity according to the three-dimensional feature parameters comprises:

[0055] Obtaining equipment three-dimensional reference coordinates of the finishing equipment;

[0056] Detecting whether the flatness and perpendicularity of the mold core on the finishing equipment meet preset flatness and preset perpendicularity according to the equipment three-dimensional reference coordinates and the three-dimensional feature parameters;

[0057] The step of controlling a mechanical arm to adjust the position and angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity when the flatness and perpendicularity of the mold core on the finishing equipment do not meet the preset flatness and the preset perpendicularity to calibrate the flatness and perpendicularity of the mold core on the finishing equipment comprises:

[0058] When the flatness and perpendicularity of the mold core on the finishing equipment do not meet the preset flatness and the preset perpendicularity, the mechanical arm is controlled to adjust the position and angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity, so that the three-dimensional detection coordinates coincide with the equipment three-dimensional reference coordinates, to calibrate the flatness and perpendicularity of the mold core on the finishing equipment.

[0059] In one of the embodiments, the step of taking the center of the core hole as a reference, and determining the coordinates of the column foot position corresponding to each core hole based on the reference comprises:

[0060] A plurality of reference sub-coordinate systems are respectively established with the center coordinates of each core hole as a coordinate origin;

[0061] The center of the core hole is taken as a reference, and the coordinates of the column foot position corresponding to each core hole are determined based on each reference sub-coordinate system and by using the preset design parameters.

[0062] The present application has the beneficial effect that, by taking the center coordinates of each core hole as a reference, the error of the distance between the core hole and the column foot can be effectively reduced, and the concentricity between the column foot position and the core hole can be improved, thus reducing the error caused by the determination of the position of the column foot position with the diagonal of the mold core, and making the concentricity of the upper mold and the lower mold higher, and further making the concentricity of the optical lens manufactured by the mold core better, and improving the precision and optical performance of the optical lens. BRIEF DESCRIPTION OF DRAWINGS

[0063] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required by the embodiments or the prior art description. Obviously, the drawings in the following description only show some embodiments of the present application, and for those skilled in the art, other drawings can be obtained based on these drawings without creative labor.

[0064] Figure 1 A flowchart of an optical lens mold manufacturing method of an embodiment;

[0065] Figure 2 A coordinate determination diagram of core holes and column feet in the prior art optical lens mold manufacturing process based on a coordinate system established with the diagonal of the mold core as the coordinate origin;

[0066] Figure 3 A coordinate determination diagram of core holes and column feet in the optical lens mold manufacturing method of an embodiment based on a coordinate system established with the center of each core hole as the coordinate origin. DETAILED DESCRIPTION

[0067] The technical solutions in the embodiments of the present application will be clearly and completely described with reference to the drawings of the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, not all. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present application.

[0068] As shown in the figure, it is an optical lens mold manufacturing method of an embodiment of the present application, which comprises: Figure 1

[0069] Step 110, providing a mold core.

[0070] In this embodiment, the mold core is the core of the mold, also known as the male mold. The mold core referred to in this step is a mold core that has not been processed, which can also be called a mold core embryo.

[0071] Step 120, rough machining the mold core to obtain a rough machined mold core.

[0072] In this step, according to the pre-set three-dimensional design drawing, CNC (Computerized Numerical Control) programming is performed, and the CNC is used to rough machine the mold core to obtain a rough machined mold core. The size of the rough machined mold core is equal to or close to that of the finished product. The core hole and column foot position have not been milled on the rough machined mold core.

[0073] ​In this step, the mold core is rough machined by a rough machining device, which includes cutting and shaping, forming the main body of the mold core, etc.

[0074] In step 130, the rough machined mold core is installed on a fine machining device, and the flatness and perpendicularity of the mold core on the fine machining device are calibrated.

[0075] In this embodiment, the fine machining device has higher machining precision than the rough machining device, and in some embodiments, the fine machining device is a CNC. In this step, the flatness and perpendicularity of the mold core on the fine machining device are calibrated to keep the to-be-machined surface of the mold core horizontal or vertical, so that the cutter can better and more accurately mill the mold core, effectively improving the machining precision. Moreover, after the flatness and perpendicularity of the mold core are calibrated, the detection precision of the mold core in the subsequent step is improved, further improving the machining precision.

[0076] In step 140, the size parameters of the to-be-machined surface of the mold core are detected, and based on the size parameters of the to-be-machined surface, a machining coordinate system of the to-be-machined surface is established.

[0077] In this embodiment, the to-be-machined surface is the surface of the mold core that needs to be machined and forms the core hole and the column foot. In this embodiment, the size parameters of the to-be-machined surface of the mold core include the position of the edge of the to-be-machined surface, the length of the edge of the to-be-machined surface, the position of the geometric center of the to-be-machined surface, and the included angle between the edges of the to-be-machined surface. In this step, based on the size parameters of the to-be-machined surface, a machining coordinate system based on the to-be-machined surface is established, which is used to define the coordinates of each position on the to-be-machined surface.

[0078] In step 150, based on the machining coordinate system, the center coordinates of each core hole are determined by using preset design parameters.

[0079] In this embodiment, the preset design parameters are also called preset machining parameters, which are designed according to the specifications of the product to be machined. The preset design parameters record the relative position information of each core hole and the position information of the column foot corresponding to each core hole. The position information of the column foot is relative to the position information of the core hole, rather than absolute position information or position information on the to-be-machined surface. The position information of the core hole on the coordinate system is the preset coordinate system. When the preset coordinate system and the machining coordinate system are the same coordinate system or the origin coordinates of the preset coordinate system coincide with the origin coordinates of the machining coordinate system, the center coordinates of the core hole are the coordinates on the machining coordinate system.

[0080] In this embodiment, according to the preset design parameters, the origin coordinates of the machining coordinate system are selected as the origin coordinates of the preset coordinate system, and the center coordinates of each core hole are selected on the machining coordinate system.

[0081] At step 160, according to the center coordinates of each core hole, the fine machining equipment is used to form a plurality of core holes on the surface to be machined.

[0082] In this embodiment, after the center coordinates of the core holes are determined, the fine machining equipment selects a tool according to the program and uses the tool to machine the surface to be machined to form a plurality of core holes on the surface to be machined.

[0083] At step 170, the center of the core hole is taken as the reference for the number of collisions, and the coordinates of the corresponding column foot positions of each core hole are determined based on the reference for the number of collisions.

[0084] In this embodiment, the column foot position is also referred to as the column foot, which is used to position the upper mold and the lower mold when the mold is closed. Each core hole corresponds to a plurality of column foot positions, that is, the outer side of each core hole surrounds a plurality of column foot positions, and the plurality of column foot positions corresponding to the core hole are arranged around the core hole with the center coordinates of the core hole as the center.

[0085] It is worth mentioning that in traditional mold core machining, as shown in Figure 2 , one diagonal of the rectangular or square mold core surface to be machined is taken as the reference for the number of collisions, a coordinate system is established with the position of the diagonal as the coordinate origin, the coordinates of the diagonal are (0.00, 0.00), and the coordinates of each core hole and each column foot are determined in this coordinate system, such as the center coordinates of one of the core holes being (48.72, 42.72), and then the machining is performed based on the coordinates of each core hole and each column foot. This method has disadvantages: on the one hand, since the positions of the core hole and the corresponding column foot are not determined according to the direct relative position, but are determined according to the absolute position using the coordinate system, there is no direct correspondence between the positions of the core hole and the column foot, resulting in an error between the core hole and the corresponding column foot, and the error is often greater than 0.005 mm; on the other hand, the distance between the coordinate system origin and the core hole and each column foot is large, resulting in a large distance between the reference for the number of collisions and the machining and a large tool travel, which is prone to deviation.

[0086] Therefore, in this embodiment, as shown in Figure 3 , the center coordinates of each core hole are taken as the reference for the number of collisions, and Figure 3 It can be seen that the center coordinates of each core hole are (0.00, 0.00) in their respective coordinate systems, and the positions (coordinates) of each column foot around the core hole are determined based on the center coordinates of the core hole, thereby enabling the column foot to accurately surround the core hole. Since the positions of the core hole and the column foot are direct relative positions, the distance between them is more accurate, which can effectively control the error to be less than 0.005 mm, and the concentricity between the column foot and the core hole can be higher. In addition, since the distance between the center of the core hole as the reference for the number of collisions and the column foot is small, deviation caused by a large distance and a long tool travel can be effectively avoided, thereby further improving the machining precision.

[0087] At step 180, according to the coordinates of the plurality of column foot positions, the plurality of column foot positions are formed on the surface to be processed by using the fine processing device.

[0088] In this embodiment, according to the coordinates of the column foot positions determined in the previous step, the plurality of column foot positions are formed on the surface to be processed.

[0089] In this embodiment, by taking the center coordinates of the core holes as the reference, the error of the distance between the core holes and the column feet can be effectively reduced, and the concentricity between the column foot positions and the core holes can be improved. In this way, the error caused by determining the position of the column foot positions with the diagonal of the mold core is reduced, and the concentricity of the front mold and the rear mold is higher. Furthermore, the concentricity of the optical lens manufactured by the mold core is better, and the precision and optical performance of the optical lens are improved.

[0090] In one embodiment, the step of detecting the size parameters of the surface to be processed of the mold core, and establishing a processing coordinate system of the surface to be processed based on the size parameters of the surface to be processed comprises:

[0091] An image of the surface to be processed of the mold core located on the fine processing device is acquired by using an image sensor, and a surface-to-be-processed image is obtained.

[0092] The surface-to-be-processed image is subjected to binaryzation processing, and a binaryzation image of the surface to be processed is obtained.

[0093] According to the structure of a surface, a line, and a point, the geometric features of the binaryzation image are extracted, and the surface features, the line features, and the point features of the surface to be processed are obtained.

[0094] The feature image of the surface to be processed is reconstructed by using the surface features, the line features, and the point features, and a geometric feature map is obtained.

[0095] According to the geometric feature map, the size parameters of the surface to be processed of the mold core are detected, and a processing coordinate system of the surface to be processed is established based on the size parameters of the surface to be processed.

[0096] In this embodiment, first, the image of the processing surface of the mold core is collected, and then the processing surface is subjected to binaryzation processing, so that the processing surface image is in black and white binary, facilitating feature recognition of the processing surface in subsequent steps. In this embodiment, according to the structure of the surface, line and point on the processing surface, the preset geometric feature recognition algorithm is used to extract the geometric features of the binary image, to obtain the surface feature, line feature and point feature of the processing surface, wherein the surface feature reflects the size and overall contour of the processing surface, the line feature reflects the features of the edge and structural line on the processing surface, and the point feature reflects the features of the intersection and angle position of the edges of the processing surface. In this embodiment, there is repetition among the surface feature, line feature and point feature in terms of object structure, which can improve the redundancy of the features, is conducive to the correction of the features, improves the accuracy of the features, and improves the robustness. Then, the extracted surface feature, line feature and point feature are used to reconstruct the image to obtain a geometric feature image, which is an image containing only surfaces, lines and points. In the process of reconstructing the image, the surface feature, line feature and point feature are mutually corrected according to the structural object repetition characteristics, to improve the accuracy. The reconstructed geometric feature image can accurately express the geometric features of the processing surface. Then, the size parameters of the processing surface of the mold core are detected according to the geometric feature image, so that the processing coordinate system of the processing surface is established according to the detected size parameters of the processing surface. The processing coordinate system can accurately reflect the coordinates and relative position relationship of different positions on the processing surface. Through the above process, the accuracy and robustness of the processing coordinate system can be effectively improved, which is conducive to subsequent processing, improves the processing accuracy, and effectively improves the concentricity of the lens.

[0097] In one embodiment, the step of detecting the size parameters of the processing surface of the mold core according to the geometric feature image, and establishing the processing coordinate system of the processing surface based on the size parameters of the processing surface comprises:

[0098] detecting the size parameters of the processing surface of the mold core according to the geometric feature image;

[0099] detecting whether the size parameters meet the concentricity accuracy condition;

[0100] when the size parameters do not meet the concentricity accuracy condition, determining the geometric center of the processing surface according to the size parameters of the processing surface, and establishing the processing coordinate system of the processing surface with the geometric center of the processing surface as the coordinate origin.

[0101] In the embodiment, the concentric precision condition refers to whether the common center surrounded by the core hole and the column foot after simulated processing coincides with the geometric center of the die block. If the common center coincides with the geometric center of the die block, the concentric precision condition is met. If the common center does not coincide with the geometric center of the die block, the concentric precision condition is not met. In this way, the processing coordinate system can be established based on different ways for the die block meeting the concentric precision condition and the concentric precision condition. For example, when the size parameter does not meet the concentric precision condition, it means that the front die and the rear die cannot be aligned according to the edge and the diagonal alignment method when the front die and the rear die are combined, and the column foot must be strictly aligned. Therefore, when the processing coordinate system is established, the geometric center of the surface to be processed should be used as the coordinate origin to establish the coordinate system.

[0102] In the embodiment, the processing coordinate system of the surface to be processed is established with the geometric center of the surface to be processed as the coordinate origin. In this way, the coordinate system can be accurately established with the geometric center of the surface to be processed as the coordinate origin when the concentric precision requirement is not met, and the positions of the core hole and the column foot can be centrally arranged. In this way, when the front die and the rear die are combined, the column foot positions of the front die and the rear die only need to be aligned to accurately combine the front die and the rear die.

[0103] In one embodiment, the step of detecting whether the size parameter meets the concentric precision condition further comprises:

[0104] When the size parameter meets the concentric precision condition, the intersection point of the two adjacent edges of the surface to be processed is determined according to the size parameter of the surface to be processed, and the processing coordinate system of the surface to be processed is established with the intersection point as the coordinate origin.

[0105] In the embodiment, the surface to be processed is rectangular or square, and the intersection point of the adjacent edges of the surface to be processed is the diagonal of the surface to be processed. The difference between the coordinate origin of the processing coordinate system in the embodiment and the above embodiment is that the coordinate origin of the processing coordinate system in the embodiment is the intersection point (i.e. the diagonal) of the pair of adjacent edges of the surface to be processed. It is worth mentioning that since the size parameter of the surface to be processed meets the concentric precision requirement, the coordinate established with the diagonal of the surface to be processed as the coordinate origin can meet the concentric precision requirement.

[0106] In addition, it should be understood that in the embodiment, the processing coordinate system is only established with the intersection point to facilitate the determination of the coordinates of the core hole, and the coordinates of the column foot are still determined according to the center of the corresponding core hole. In the embodiment, the processing coordinate system established with the intersection point is not used to directly determine the coordinates of the column foot. In this way, the coordinate system can be established even if the concentric precision requirement is not met, without reworking the die block.

[0107] It is worth mentioning that in the above embodiment, different ways are selected to establish the machining coordinate system by whether the concentric accuracy condition is met, thereby avoiding the waste of the mold core due to the different concentricity conditions, avoiding the waste of the mold core, and regardless of whether the concentric accuracy condition is met, the mold core is retained, and then in the production process, only the front mold and the rear mold meeting the concentric accuracy condition are paired, and the front mold and the rear mold not meeting the concentric accuracy condition are paired, so that the accuracy can be improved, and the cost increase due to the abandonment can be avoided.

[0108] In one embodiment, the step of detecting whether the size parameter meets the concentric accuracy condition comprises:

[0109] According to the size parameter of the to-be-machined surface, a test coordinate system is established with the intersection point of two adjacent edges of the to-be-machined surface as the coordinate origin;

[0110] Based on the test coordinate system, the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions are determined by using the preset design parameters;

[0111] According to the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions, a test center coordinate of the to-be-machined surface is calculated;

[0112] According to the size parameter of the to-be-machined surface, a geometric center coordinate of the to-be-machined surface is determined;

[0113] It is detected whether the deviation between the test center coordinate and the geometric center coordinate is less than a preset threshold value;

[0114] Wherein, if the deviation between the test center coordinate and the geometric center coordinate is less than a preset threshold value, the size parameter meets the concentric accuracy condition; if the deviation between the test center coordinate and the geometric center coordinate is greater than or equal to the preset threshold value, the size parameter does not meet the concentric accuracy condition.

[0115] In this embodiment, in order to detect whether the size parameter meets the concentric accuracy requirement, a test coordinate system needs to be established, first, a test coordinate system is established with the diagonal of the to-be-machined surface as the coordinate origin, and on the basis of the test coordinate system, the first test coordinates of the core holes and the second test coordinates of the column foot positions are determined by using the preset design parameters. The reference system of the first test coordinates and the second test coordinates is the test coordinate system with the diagonal as the origin. Since each core hole should be arranged in a circular array with a certain coordinate as the center, and each column foot position is also symmetrically distributed with a certain coordinate as the center in addition to being arranged in a circular array with the corresponding core hole as the center, the coordinates of the center can be calculated according to the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions. The coordinates of the center are the test center coordinates.

[0116] It should be understood that the geometric center coordinates of the surface to be processed are the coordinates corresponding to the geometric center of the surface to be processed. Ideally, the test center coordinates should coincide with the geometric center coordinates of the surface to be processed, but there are cases where the test center coordinates do not correspond to the geometric center coordinates of the surface to be processed. Therefore, it is necessary to detect whether the deviation between the test center coordinates and the geometric center coordinates is less than a preset threshold. When the deviation between the test center coordinates and the geometric center coordinates is less than the preset threshold, it means that the test center coordinates coincide with the geometric center coordinates, and the size parameters meet the concentric accuracy condition. Therefore, even if the diagonal is taken as the coordinate origin to establish the coordinate system, the coordinates of the core hole and the coordinates of the column foot can be accurately determined, which facilitates accurate processing of each mold core.

[0117] When the deviation between the test center coordinates and the geometric center coordinates is greater than or equal to the preset threshold, it means that the test center coordinates do not coincide with the geometric center coordinates, and the size parameters do not meet the concentric accuracy condition. At this time, the positioning of the front mold and the rear mold only relies on the column foot, therefore, only the center coordinates of the core hole need to be determined according to the processing coordinate system, and the coordinates of the column foot are determined based on the center coordinates of the core hole, so that the relative positional relationship between the column feet and the relative positional relationship between the core holes meet the preset design parameters, and the front mold and the rear mold are aligned through the column feet.

[0118] In one embodiment, before the step of binarizing the surface to be processed image to obtain the binarized image of the surface to be processed, it further comprises:

[0119] inputting the surface to be processed image into an image recognition model, identifying the noise region in the surface to be processed image by using the image recognition model, and adding a noise identifier to the noise region;

[0120] The step of binarizing the surface to be processed image to obtain the binarized image of the surface to be processed comprises:

[0121] According to the noise identifier, the surface to be processed image is binarized, and the noise region corresponding to the noise identifier is removed to obtain the binarized image of the surface to be processed.

[0122] In this embodiment, the noise region refers to a region where other structures are located except the machined surface and the structure on the machined surface, such as the burr formed by rough machining, other structures on the finishing equipment, environmental structures around the mold core, etc. The image of the noise region is not part of the mold core or the machined surface, and therefore, the part of the region is taken as the noise region. The image recognition model is a neural network model obtained by pre-training, and the image recognition model is used to identify the machined surface and the noise region in the image. Specifically, in an embodiment, a plurality of sample machined surface images with noise region labels are input into the neural network for learning, and when the neural network model is stable, the image recognition model is obtained.

[0123] In this embodiment, the noise region in the machined surface image can be identified by the image recognition model, and after the noise region is identified, a noise label is added to the noise region. The noise label can be the contour line of the noise region. Subsequently, during the binarization process, according to the noise label, the binarization process is first uniformly performed on each noise region, and the pixel value of each noise region is set to 0 or 255, so that the pixel value of the noise region is the same as the background, so as to eliminate the noise region. Subsequently, the binarization process eliminates the contour line of the noise region. In this way, the noise region is eliminated while the machined surface image is binarized. On the one hand, the noise region can be accurately eliminated, so that the binarized image of the machined surface image is more accurate. On the other hand, compared with the method of eliminating the noise region outside the binarization step, the noise region is binarized at the same time, which can effectively improve the processing efficiency and can preserve the image details as much as possible, thereby improving the accuracy of the binarized image.

[0124] In an embodiment, the step of installing the mold core after rough machining on the finishing equipment and calibrating the flatness and perpendicularity of the mold core on the finishing equipment comprises:

[0125] The three-dimensional characteristic parameters of the mold core are measured by using a range finder when the mold core after rough machining is installed on the finishing equipment.

[0126] According to the three-dimensional characteristic parameters, it is detected whether the flatness and perpendicularity of the mold core on the finishing equipment meet the preset flatness and preset perpendicularity.

[0127] When the flatness and perpendicularity of the mold core on the finishing equipment do not meet the preset flatness and preset perpendicularity, the position and angle of the mold core on the finishing equipment are adjusted by a mechanical arm according to the preset flatness and preset perpendicularity, so as to calibrate the flatness and perpendicularity of the mold core on the finishing equipment.

[0128] When the flatness and the perpendicularity of the mold core on the finishing equipment meet preset flatness and preset perpendicularity, a three-dimensional model of the mold core is constructed according to the three-dimensional characteristic parameters.

[0129] In the embodiment, the range finder can be a laser range finder, or other types of distance or length measuring instruments. The three-dimensional characteristic parameters are parameters of the mold core and structures on the mold core in the X-axis direction, the Y-axis direction and the Z-axis direction, which include the length, the width and the height of the mold core, the width of the surface to be machined of the mold core, and the width of the structures on the surface to be machined of the mold core. In the embodiment, the dimensions of the mold core are measured by horizontal movement and vertical movement of multiple sets of laser range finders during the movement, and then the three-dimensional characteristic parameters of the mold core are obtained.

[0130] Subsequently, the flatness and the perpendicularity of the mold core on the finishing equipment are detected by using the three-dimensional characteristic parameters. The detection of the flatness is to ensure that the surface to be machined is horizontal, and the detection of the perpendicularity is to keep the surface to be machined horizontal, and also to make the position, direction and angle of the mold core on the finishing equipment align with the preset machining station. For example, whether the edges of the mold core are perpendicular to the corresponding reference lines on the finishing equipment is detected. When the edges of the mold core are perpendicular to the corresponding reference lines, it indicates that the perpendicularity of the mold core meets the preset perpendicularity. When the flatness and the perpendicularity of the mold core do not meet the preset flatness and the preset perpendicularity, the position and the angle of the mold core on the finishing equipment are adjusted by a mechanical arm according to the preset flatness and the preset perpendicularity, so as to calibrate the flatness and the perpendicularity of the mold core on the finishing equipment, so that the flatness and the perpendicularity of the mold core on the finishing equipment meet the preset flatness and the preset perpendicularity. When the flatness and the perpendicularity of the mold core on the finishing equipment meet the preset flatness and the preset perpendicularity, the next step is directly executed, and a three-dimensional model of the mold core is constructed according to the three-dimensional characteristic parameters. In the embodiment, the calibration of the flatness and the perpendicularity of the mold core is beneficial to accurate machining in the subsequent steps and avoids errors. In addition, the construction of the three-dimensional model of the mold core is beneficial to the calibration of the geometric features of the model.

[0131] In one embodiment, the step of reconstructing the feature image of the surface to be machined by using the area feature, the line feature and the point feature to obtain a geometric feature map comprises:

[0132] The three-dimensional model of the mold core is analyzed to obtain two-dimensional characteristic parameters of the surface to be machined;

[0133] The two-dimensional characteristic parameters are compared with the area feature, the line feature and the point feature to establish a corresponding relationship between the two-dimensional characteristic parameters and the area feature, the line feature and the point feature;

[0134] Constraining the face feature, the line feature and the point feature according to the two-dimensional feature parameter based on the corresponding relationship between the two-dimensional feature parameter and the face feature, the line feature and the point feature;

[0135] Reconstructing a feature image of the surface to be processed by using the face feature, the line feature and the point feature to obtain a geometric feature image.

[0136] In the embodiment, first, the three-dimensional model of the die core is analyzed to obtain the two-dimensional feature parameter of the surface to be processed of the die core, which includes the face feature parameter, the line feature parameter and the point feature parameter, and the feature parameter can include the position parameter, the length parameter, the distance parameter and the angle parameter. In the embodiment, the face feature, the line feature and the point feature are constrained by using the two-dimensional feature parameter of the surface to be processed, so that the face feature, the line feature and the point feature can be more accurately expressed, thereby making the geometric feature image of the surface to be processed more accurate.

[0137] In one of the embodiments, the step of measuring the three-dimensional feature parameter of the die core by using the range finder includes:

[0138] Obtaining a reference three-dimensional model, wherein the reference three-dimensional model records the three-dimensional parameter of the standard die core and records the measurement reference of the die core;

[0139] Measuring the geometric parameter of at least one side edge of the die core by using the range finder;

[0140] Constructing a three-dimensional detection coordinate by using the geometric parameter of at least one side edge of the die core;

[0141] Extracting the measurement reference from the reference three-dimensional model, determining the measurement position and the measurement angle of the range finder based on the three-dimensional detection coordinate and the measurement reference;

[0142] Adjusting the position and the angle of the range finder based on the measurement position and the measurement angle, and measuring the three-dimensional feature parameter of the die core by using the range finder;

[0143] The step of detecting whether the flatness and the perpendicularity of the die core on the finishing equipment meet the preset flatness and the preset perpendicularity according to the three-dimensional feature parameter includes:

[0144] Obtaining a device three-dimensional reference coordinate of the finishing equipment;

[0145] Detecting whether the flatness and the perpendicularity of the die core on the finishing equipment meet the preset flatness and the preset perpendicularity according to the device three-dimensional reference coordinate and the three-dimensional feature parameter;

[0146] When the flatness and perpendicularity of the mold core on the finishing equipment do not meet the preset flatness and preset perpendicularity, the step of controlling the mechanical arm to adjust the position and angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity to calibrate the flatness and perpendicularity of the mold core on the finishing equipment comprises:

[0147] When the flatness and perpendicularity of the mold core on the finishing equipment do not meet the preset flatness and preset perpendicularity, the step of controlling the mechanical arm to adjust the position and angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity to calibrate the flatness and perpendicularity of the mold core on the finishing equipment comprises:

[0148] In the embodiment, the reference three-dimensional model is a three-dimensional model of a standard mold core. In the embodiment, the three-dimensional model of the standard mold core is used as the reference. The measurement reference is the position of the key points of the mold core. By measuring the distance, length, relative position, etc. of the plurality of key points on the mold core, the overall three-dimensional feature parameters of the mold core can be obtained by calculation. Therefore, in the embodiment, the geometric parameters of one side edge of the mold core are first measured, such as the distance between the two ends of one side edge of the mold core (referring to the distance between the measurement points), the height of the two ends, and the distance between the two ends. The geometric parameters of the measured side edge are used as the reference for establishing the three-dimensional detection coordinates. The three-dimensional detection coordinates are established with reference to the mold core placed on the finishing equipment. Then, the positions of the key points to be measured are found according to the measurement references recorded in the three-dimensional model of the standard mold core, and the plurality of measurement positions of the distance meter and the measurement angles corresponding to the measurement positions are determined in combination with the three-dimensional detection coordinates. The mold core is measured at different measurement positions and at different measurement angles, and the overall three-dimensional feature parameters of the mold core are obtained. Unlike the three-dimensional feature parameters in the previous embodiment, the three-dimensional feature parameters in the previous embodiment also include the relative position and angle between the reference line of the finishing equipment. After adjusting the position and angle of the mold core, the three-dimensional feature parameters of the mold core need to be measured again, and the three-dimensional model of the mold core is constructed according to the re-measured three-dimensional feature parameters. The three-dimensional feature parameters in the embodiment are established based on the three-dimensional detection coordinates of the mold core itself. Therefore, in the embodiment, the position and angle of the mold core are adjusted, and the three-dimensional feature parameters of the mold core are not affected. In this way, when the three-dimensional model of the mold core is constructed subsequently, the three-dimensional feature parameters do not need to be measured again due to the change of the position and angle of the mold core on the finishing equipment, thereby improving the efficiency of constructing the three-dimensional model of the mold core. Moreover, the corresponding face feature, line feature and point feature can be accurately constrained by the two-dimensional feature parameters of the surface to be processed.

[0149] In addition, the three-dimensional feature parameter in the embodiment is measured based on the three-dimensional detection coordinates of the die itself, and therefore, the three-dimensional feature parameter contains the three-dimensional detection coordinates. Therefore, when the preset flatness and the preset perpendicularity of the die are detected, the three-dimensional reference coordinates of the equipment, the three-dimensional detection coordinates and the three-dimensional feature parameter can be used for detection. When the flatness and the perpendicularity of the die do not meet the preset flatness and the preset perpendicularity, the position of the die can be adjusted so that the three-dimensional detection coordinates coincide with the three-dimensional reference coordinates of the equipment, thereby facilitating subsequent fine processing of the die. It should be noted that the three-dimensional reference coordinates of the equipment in the embodiment are the reference coordinates established based on the fine processing equipment. In this way, after the three-dimensional detection coordinates coincide with the three-dimensional reference coordinates of the equipment, the three-dimensional feature parameter of the die does not need to be detected again, and the three-dimensional feature parameter can be directly used to construct a three-dimensional model in the subsequent steps.

[0150] In one embodiment, the step of taking the center of the core hole as a reference and determining the coordinates of the column foot corresponding to each core hole based on the reference includes:

[0151] Taking the center of each core hole as a coordinate origin, a plurality of reference sub-coordinate systems are established;

[0152] Taking the center of the core hole as a reference, the coordinates of the column foot corresponding to each core hole are determined based on the reference sub-coordinate system and the preset design parameters.

[0153] In the embodiment, after the machining coordinate system is established, the center coordinates of the core hole are determined on the machining coordinate system using the preset design parameters. Subsequently, a plurality of reference sub-coordinate systems are established again with the center coordinates of the core hole as the coordinate origin, and each reference sub-coordinate system is used to calibrate the coordinates of the column foot corresponding to the core hole. It should be understood that the outside of each core hole surrounds a plurality of column feet, so that the coordinates of the column feet can be determined based on the center coordinates of the core hole, thereby reducing the distance error between the column feet and the core hole and effectively improving the accuracy of the column feet. In addition, taking the center of the core hole as a reference, each column foot can be accurately machined.

[0154] The technical features of the above-described embodiments can be combined in any manner. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described, but as long as the combinations of the technical features do not exist, they should be considered as the scope of the present disclosure.

[0155] The above embodiments only express several implementation manners of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the present application, several modifications and improvements can be made, which are within the scope of protection of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A method for manufacturing an optical lens mold, characterized in that, The application relates to a method for machining a mold core. The method comprises the following steps: providing a mold core; rough machining the mold core to obtain a rough-machined mold core; mounting the rough-machined mold core on a finishing equipment to calibrate the flatness and perpendicularity of the mold core on the finishing equipment; detecting the size parameters of a to-be-machined surface of the mold core, and establishing a machining coordinate system of the to-be-machined surface based on the size parameters of the to-be-machined surface; determining the center coordinates of each core hole based on the machining coordinate system and preset design parameters; forming a plurality of core holes on the to-be-machined surface by using the finishing equipment according to the center coordinates of each core hole; taking the center of each core hole as a reference, and determining the coordinates of each column foot position corresponding to the core hole based on the reference; 2. The optical lens mold making method according to claim 1, wherein forming a plurality of column foot positions on the to-be-machined surface by using the finishing equipment according to the coordinates of each column foot position. The step of detecting the size parameters of the to-be-machined surface of the mold core and establishing the machining coordinate system of the to-be-machined surface based on the size parameters of the to-be-machined surface comprises the following steps: acquiring an image of the to-be-machined surface of the mold core on the finishing equipment by using an image sensor to obtain a to-be-machined surface image; performing binaryzation processing on the to-be-machined surface image to obtain a binaryzation image of the to-be-machined surface; extracting geometric features of the binaryzation image according to the structure of a surface, a line and a point to obtain surface features, line features and point features of the to-be-machined surface; reconstructing a feature image of the to-be-machined surface by using the surface features, the line features and the point features to obtain a geometric feature image; 3. The optical lens mold making method according to claim 2, wherein, detecting the size parameters of the to-be-machined surface of the mold core according to the geometric feature image, and establishing the machining coordinate system of the to-be-machined surface based on the size parameters of the to-be-machined surface. The step of detecting the size parameters of the to-be-machined surface of the mold core according to the geometric feature image and establishing the machining coordinate system of the to-be-machined surface based on the size parameters of the to-be-machined surface comprises the following steps: detecting the size parameters of the to-be-machined surface of the mold core according to the geometric feature image; detecting whether the size parameters meet a concentricity accuracy condition; 4. The optical lens mold making method according to claim 3, wherein, when the size parameters do not meet the concentricity accuracy condition, determining the geometric center of the to-be-machined surface according to the size parameters of the to-be-machined surface, and establishing the machining coordinate system of the to-be-machined surface with the geometric center of the to-be-machined surface as a coordinate origin. The step of detecting whether the size parameters meet the concentricity accuracy condition further comprises the following steps:

5. The optical lens mold making method according to claim 3, wherein, when the size parameters meet the concentricity accuracy condition, determining the intersection point of two adjacent edges of the to-be-machined surface according to the size parameters of the to-be-machined surface, and establishing the machining coordinate system of the to-be-machined surface with the intersection point as a coordinate origin. The step of detecting whether the size parameters meet the concentricity accuracy condition comprises the following steps: establishing a test coordinate system with the intersection point of two adjacent edges of the to-be-machined surface as a coordinate origin according to the size parameters of the to-be-machined surface; determining the first test coordinates of the center of each core hole and the second test coordinates of each column foot position based on the test coordinate system and the preset design parameters; According to the first test coordinates of the centers of the core holes and the second test coordinates of the column foot positions, a test center coordinate of the to-be-processed surface is calculated; According to the size parameters of the to-be-processed surface, a geometric center coordinate of the to-be-processed surface is determined; It is detected whether a deviation between the test center coordinate and the geometric center coordinate is less than a preset threshold value; If the deviation between the test center coordinate and the geometric center coordinate is less than the preset threshold value, the size parameters meet the concentricity precision condition; if the deviation between the test center coordinate and the geometric center coordinate is greater than or equal to the preset threshold value, the size parameters do not meet the concentricity precision condition.

6. The optical lens mold making method according to claim 2, wherein, Before the step of performing the binarization processing on the to-be-processed surface image to obtain the binarized image of the to-be-processed surface, the method further comprises: inputting the to-be-processed surface image into an image recognition model, identifying noise regions in the to-be-processed surface image by using the image recognition model, and adding noise labels to the noise regions; The step of performing the binarization processing on the to-be-processed surface image to obtain the binarized image of the to-be-processed surface comprises: According to the noise labels, performing the binarization processing on the to-be-processed surface image, and performing the rejection processing on the noise regions corresponding to the noise labels to obtain the binarized image of the to-be-processed surface.

7. The optical lens mold making method according to claim 2, wherein The step of installing the rough-machined mold core on the fine machining equipment to calibrate the flatness and perpendicularity of the mold core on the fine machining equipment comprises: installing the rough-machined mold core on the fine machining equipment, and measuring the three-dimensional characteristic parameters of the mold core by using a range finder; According to the three-dimensional characteristic parameters, it is detected whether the flatness and perpendicularity of the mold core on the fine machining equipment meet preset flatness and preset perpendicularity; When the flatness and perpendicularity of the mold core on the fine machining equipment do not meet the preset flatness and preset perpendicularity, the position and angle of the mold core on the fine machining equipment are adjusted by using a mechanical arm according to the preset flatness and preset perpendicularity, so as to calibrate the flatness and perpendicularity of the mold core on the fine machining equipment; When the flatness and perpendicularity of the mold core on the fine machining equipment meet the preset flatness and preset perpendicularity, a three-dimensional model of the mold core is constructed according to the three-dimensional characteristic parameters.

8. The optical lens mold making method according to claim 7, wherein, The step of reconstructing the feature image of the to-be-processed surface by using the surface feature, the line feature and the point feature to obtain a geometric feature map comprises: analyzing the three-dimensional model of the mold core to obtain two-dimensional characteristic parameters of the to-be-processed surface; comparing the two-dimensional characteristic parameters with the surface feature, the line feature and the point feature to establish a corresponding relationship between the two-dimensional characteristic parameters and the surface feature, the line feature and the point feature; based on the corresponding relationship between the two-dimensional characteristic parameters and the surface feature, the line feature and the point feature, the corresponding surface feature, line feature and point feature are constrained by using the two-dimensional characteristic parameters; the feature image of the to-be-processed surface is reconstructed by using the surface feature, the line feature and the point feature to obtain a geometric feature map.

9. The method of claim 7, wherein the mold is made by injection molding. The step of measuring the three-dimensional characteristic parameters of the mold core by using the distance meter comprises: acquiring a reference three-dimensional model, wherein the reference three-dimensional model records three-dimensional parameters of a standard mold core and records a measurement reference of the mold core; measuring geometric parameters of at least one side edge of the mold core by using the distance meter; constructing a three-dimensional detection coordinate by using the geometric parameters of at least one side edge of the mold core; extracting the measurement reference from the reference three-dimensional model, determining a measurement position and a measurement angle of the distance meter based on the three-dimensional detection coordinate and the measurement reference; adjusting the position and the angle of the distance meter based on the measurement position and the measurement angle, and measuring the three-dimensional characteristic parameters of the mold core by using the distance meter; The step of detecting whether the flatness and the perpendicularity of the mold core on the finishing equipment conform to preset flatness and preset perpendicularity according to the three-dimensional characteristic parameters comprises: acquiring a device three-dimensional reference coordinate of the finishing equipment; detecting whether the flatness and the perpendicularity of the mold core on the finishing equipment conform to preset flatness and preset perpendicularity according to the device three-dimensional reference coordinate and the three-dimensional characteristic parameters; The step of controlling a mechanical arm to adjust the position and the angle of the mold core on the finishing equipment to calibrate the flatness and the perpendicularity of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity when the flatness and the perpendicularity of the mold core on the finishing equipment do not conform to the preset flatness and the preset perpendicularity comprises: controlling the mechanical arm to adjust the position and the angle of the mold core on the finishing equipment according to the preset flatness and the preset perpendicularity when the flatness and the perpendicularity of the mold core on the finishing equipment do not conform to the preset flatness and the preset perpendicularity, so that the three-dimensional detection coordinate coincides with the device three-dimensional reference coordinate, to calibrate the flatness and the perpendicularity of the mold core on the finishing equipment.

10. The method of claim 1-9, wherein The step of determining the coordinates of the column foot positions corresponding to the core holes based on the impact number reference comprises: establishing a plurality of reference sub-coordinate systems respectively with the center coordinates of the core holes as coordinate origins; determining the coordinates of the column foot positions corresponding to the core holes based on the reference sub-coordinate systems and the preset design parameters. The step of determining the coordinates of the column foot positions corresponding to the core holes based on the impact number reference comprises: establishing a plurality of reference sub-coordinate systems respectively with the center coordinates of the core holes as coordinate origins; determining the coordinates of the column foot positions corresponding to the core holes based on the reference sub-coordinate systems and the preset design parameters.

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