A flight vision laser processing method

Abstract

The present invention relates to the technical field of laser beam processing, and particularly to a flying vision laser processing method, which includes step S1 of obtaining a vision camera after mapping correction; step S2 of obtaining an online laser processing device after initialization; step S3 of obtaining a motion monitoring photo; step S4 of calculating a position to be processed; step S5 of obtaining the number of products to be processed and the rotation offset values of each product to be processed; step S6 of obtaining the processing sequence for product alignment; step S7 of obtaining the effectiveness of each position to be processed and the effective positions to be processed; step S8 of performing motion monitoring and correction control on the product processing process; and step S9 of performing supplementary control on the motion monitoring and correction control method. By performing real-time feedback on the offset during the laser processing and dynamically optimizing the laser path, the present invention alleviates the overload of the galvanometer during the processing and improves the efficiency of online laser processing.

Description

Technical Field

[0001] The present invention relates to the technical field of laser beam processing, and particularly relates to a flying vision laser processing method. Background Art

[0002] With the advantages of high precision and high efficiency, laser processing technology has been widely applied in high-end manufacturing fields such as automobile manufacturing, electronic devices, aerospace, and medical devices. In the modern production and manufacturing system, the assembly line, as the core carrier for realizing high-efficiency automated production, its continuity and stability directly determine the overall production efficiency. As a key processing device in the assembly line system, the laser processing system not only needs to meet the requirements of high-precision processing, but also needs to achieve seamless connection with the dynamic operation of the assembly line. However, the current mainstream static vision positioning laser processing scheme has significant limitations: the operation mode of "processing - stopping - restarting" by pausing the operation of the assembly line during each processing seriously restricts the production efficiency and cannot fully utilize the advantages of continuous production of the assembly line. This technical bottleneck has become the main obstacle restricting the further development of laser processing in the application of the assembly line, and it is urgent to achieve a breakthrough through technological innovation to promote the deep integration of laser processing technology and modern intelligent manufacturing.

[0003] Chinese Patent Publication No.: CN220698542U discloses a flying vision positioning laser coding device, which includes a support frame body. A laser coding component and a pre-positioning component are provided on the support frame body. The laser coding component includes a laser, a transmission optical path, and a galvanometer that are connected in sequence. The pre-positioning component includes a first camera and a second camera that are diagonally arranged. The first camera, the second camera, the laser, the transmission optical path, and the galvanometer are all arranged on the same side of the product to be coded. The product to be coded passes through the pre-positioning component and the laser coding component in a moving state in sequence. However, the working principle of this scheme is to change its output level by sensing whether there is an object blocking in front. For the scenario where adjacent products are connected end to end, the sensor cannot distinguish and there will be missed coding situations. It cannot realize the real-time feedback of the offset amount and the dynamic optimization of the laser path during the laser processing process, and there is a problem of galvanometer overload, and it cannot be applied to high-precision and high-beat online laser processing scenarios. Summary of the Invention

[0004] Therefore, the present invention provides a flying vision laser processing method to overcome the problem of low online laser processing efficiency caused by the lack of real-time feedback of the offset amount and dynamic optimization of the laser path during the laser processing process, and the overload of the galvanometer during the processing process in the prior art.

[0005] To achieve the above object, the present invention provides a flying vision laser processing method, including:

[0006] Step S1, performing mapping correction on the vision camera to obtain the vision camera after mapping correction;

[0007] Step S2, after obtaining the visually calibrated camera, set the key parameters and initialize the on-line laser processing device according to the key parameters to obtain the initialized on-line laser processing device;

[0008] Step S3, run the initialized on-line laser processing device to process the product, monitor the movement of the product processing process through the visually calibrated camera to obtain the movement monitoring photos, movement monitoring photo numbers, and monitor the movement of the product processing process through the laser control card to obtain the current pipeline position of the movement monitoring photos;

[0009] Step S4, calculate the waiting processing positions according to the key parameters and the current pipeline position of the movement monitoring photos;

[0010] Step S5, obtain the number of products waiting to be processed and the rotation offset values of each product waiting to be processed according to the movement monitoring photos;

[0011] Step S6, align and sort the scanning order of the products waiting to be processed and the rotation offset values of the products waiting to be processed according to the pipeline direction to obtain the aligned processing order of the products;

[0012] Step S7, judge the validity of the waiting processing positions according to the key parameters and the number of products waiting to be processed to obtain the validity of each waiting processing position and the valid waiting processing positions;

[0013] Step S8, perform movement monitoring and correction control on the product processing process according to the aligned processing order of the products and the valid waiting processing positions;

[0014] Step S9, perform supplementary control on the movement monitoring and correction control method according to the validity of each waiting processing position and the rotation offset values of each product waiting to be processed.

[0015] Further, in the step S1, when performing mapping calibration on the visual camera, control the on-line laser processing device to process a set of solid circular dots at a preset fixed position on the calibration plate to obtain the processed calibration plate, and use the coordinate position information set of this set of solid circular dots as the actual dot position group. Use the visual camera to take a picture of the processed calibration plate to obtain the processed calibration plate photo, obtain the position information of each solid circular dot in the processed calibration plate photo, use the position information of each solid circular dot in the processed calibration plate photo as the ideal dot position group, calculate the distortion error between the actual dot position group and the ideal dot position group, generate the mapping calibration parameters according to the distortion error, and perform mapping calibration on the visual camera according to the mapping calibration parameters to obtain the mapped and calibrated visual camera.

[0016] Further, in the step S2, when setting the key parameters, the key parameters include laser processing content, the maximum number of parts C1 processed at one time, waiting distance D1, and interval distance D2. When setting the laser processing content, the processing pattern is obtained, and a processing path is generated according to the processing pattern. When setting the maximum number of parts C1 processed at one time, the physical properties of the laser galvanometer in the online laser processing device are obtained, and the maximum number of parts C1 processed at one time is set according to the physical properties of the laser galvanometer. When setting the waiting distance D1, the distance in the assembly line direction from the center of the vision camera to the center of the laser galvanometer is obtained and used as the waiting distance D1. When setting the interval distance D2, the size of the product to be processed is obtained, and the interval distance D2 is generated according to the size of the product to be processed;

[0017] In the step S2, when initializing the online laser processing device, the laser processing content, the maximum number of parts C1 processed at one time, the waiting distance D1, and the interval distance D2 are input into the laser control card of the online laser processing device to obtain the initialized online laser processing device, and it is set that the initialized online laser processing device performs a forward scan in the assembly line direction during the product processing.

[0018] Further, in the step S3, when monitoring the movement during the product processing, the current assembly line movement distance Da is compared with the interval distance D2, and the photographing trigger result of the vision camera is judged according to the comparison result, where:

[0019] When Da < D2, it is determined that the photographing trigger result of the vision camera is not to trigger the vision camera to take a picture;

[0020] When Da = D2, it is determined that the photographing trigger result of the vision camera is to trigger the vision camera to take a picture, and an IO signal is sent through the laser control card to trigger the vision camera to take a picture, obtaining a movement monitoring photo, and numbering the movement monitoring photo to obtain the movement monitoring photo number M i , i is the number of times the vision camera takes a picture, i = 1, 2,..., n, n is an integer, and at the same time, the encoder position of the current assembly line is marked to obtain the current assembly line position N of the movement monitoring photo i ;

[0021] When Da > D2, it is determined that the photographing trigger result of the vision camera is not to trigger the vision camera to take a picture, and the current assembly line movement distance Da is reset to zero, and the current assembly line movement distance Da is accumulated again starting from the current assembly line position of the current movement monitoring photo.

[0022] Further, in the step S4, when calculating the position to be processed, according to the waiting distance D1 in the key parameters and the current assembly line position N of the movement monitoring photo i the position M to be processedi Perform calculations and set M i = D1 + N i .

[0023] Further, in the step S5, when obtaining the number of products waiting to be processed, compare the waiting processing position M i with the current assembly line position N of the motion monitoring photo i and judge the current position to be processed according to the comparison result, where:

[0024] When M i ≠ N i , it is determined that the waiting processing position is not the current position to be processed, and the waiting processing position is not processed currently;

[0025] When M i = N i , it is determined that the waiting processing position is the current position to be processed, and the waiting processing position is processed currently;

[0026] Obtain the waiting processing positions that have not been laser processed and their quantities in the current position to be processed, regard the waiting processing positions that have not been laser processed as the products waiting to be processed, and regard the quantity of the waiting processing positions that have not been laser processed as the number of products waiting to be processed H;

[0027] In the step S5, when obtaining the rotation offset values of each product waiting to be processed, perform image recognition on the motion monitoring photo to obtain the rotation offset values V of each product waiting to be processed k , where k is the scanning order of the products waiting to be processed, k = 1, 2,... H.

[0028] Further, in the step S6, when aligning and sorting the scanning order of the products waiting to be processed and the rotation offset values of the products waiting to be processed, align and sort the scanning order k of the products waiting to be processed and the rotation offset values V of the products waiting to be processed k according to the assembly line direction to obtain the aligned processing order Y of the products, and set Y as the ordered set in the data form of k - V k .

[0029] Further, in the step S7, when judging the validity of the waiting processing position, compare the maximum number of parts processed at one time C1 in the key parameters with the number of products waiting to be processed H, and judge the validity of the waiting processing position according to the comparison result, where:

[0030] When C1 ≥ H, it is determined that the waiting processing positions that have not been laser processed corresponding to the number of products waiting to be processed H are valid, and the waiting processing positions that have not been laser processed corresponding to the number of products waiting to be processed H are used as the valid waiting processing positions;

[0031] When C1 < H, it is determined that the waiting processing positions within the single - maximum number of processed parts C1 in the product alignment processing sequence that have not undergone laser processing are valid, and the waiting processing positions within the single - maximum number of processed parts C1 in the product alignment processing sequence that have not undergone laser processing are used as valid waiting processing positions. It is determined that the waiting processing positions outside the single - maximum number of processed parts C1 in the product alignment processing sequence that have not undergone laser processing are invalid.

[0032] Furthermore, in step S8, when performing motion monitoring and correction control during the product processing, the motion monitoring and correction control method is set as follows: retain the valid waiting processing positions in the product alignment processing sequence, and eliminate the waiting processing positions outside the single - maximum number of processed parts C1 in the product alignment processing sequence that have not undergone laser processing;

[0033] Transmit the motion monitoring and correction control method to the laser control card of the on - line laser processing device after initialization.

[0034] Furthermore, in step S9, when performing supplementary control on the motion monitoring and correction control method, when the current position to be processed is a valid waiting processing position, obtain the waiting - processing product rotation offset value V of the current position to be processed in the product alignment processing sequence k , compare it with each preset rotation offset value, and perform supplementary control on the motion monitoring and correction control method according to the comparison result, where:

[0035] When V k ≤V k1 , it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method. Supplement the content of correcting the forward scan along the pipeline direction to reverse scan during the product processing into the motion monitoring and correction control method;

[0036] When V k1 <V k <V k2 , it is determined that there are no processing hazards at the current position to be processed, and no supplementary control needs to be performed on the motion monitoring and correction control method;

[0037] When V k ≥V k2 , it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method. Supplement the content of correcting the forward scan along the pipeline direction to reverse scan during the product processing into the motion monitoring and correction control method;

[0038] V k1 is the first preset rotation offset value. Set V k1=-90°, V k2 is the second preset rotation offset value, set V k2 = 90°.

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows. Through step S1, the vision camera is mapped and corrected to obtain the vision camera after mapping and correction, eliminating problems such as imaging distortion and position deviation, so that the image information obtained by the vision camera can more accurately reflect the position and state of the actual product, providing a reliable basis for subsequent motion monitoring and processing control based on vision images, ensuring the accuracy of product position judgment during the processing, and thus improving the processing accuracy and product quality. Through step S2, the on-line laser processing device is initialized to obtain the on-line laser processing device after initialization, and the key parameters can be set according to different processing requirements and product characteristics. Through step S3, the initialized on-line laser processing device is run to process the product, so as to timely obtain the position and motion state information of the product during the processing, accurately track and identify the processing process of each product, and the motion monitoring based on the vision camera can realize the real-time monitoring of the product processing process, avoiding processing problems caused by untimely or inaccurate manual monitoring. Through step S4, the waiting processing position is calculated according to the key parameters and the current pipeline position of the motion monitoring photo, so as to accurately calculate the position of the product waiting for processing, improve the accuracy and efficiency of processing, reduce the idle stroke during the processing, and thus improve the efficiency of on-line laser processing. Through step S5, the number of products waiting for processing and the rotation offset values of each product waiting for processing are obtained according to the motion monitoring photo. The processing rhythm is reasonably adjusted according to the number of products to avoid low processing efficiency caused by unreasonable processing order. By obtaining this offset value and making corresponding adjustments, the accuracy of processing can be guaranteed, the scrap rate can be reduced, and the processing efficiency can be improved. Through step S6, the scanning order of the products waiting for processing and the rotation offset values of the products waiting for processing are aligned and sorted according to the pipeline direction to obtain the aligned processing order of the products, reducing the frequent turning and adjustment of the laser processing device during the processing, reducing the working load of the galvanometer, and alleviating the problem of galvanometer overload during the processing. Through step S7, the effectiveness of the waiting processing position is judged according to the key parameters and the number of products waiting for processing, so as to avoid unnecessary attempts and processing of the laser processing device on invalid positions, reduce the waste of processing time, and thus further improve the processing efficiency. Through step S8, the motion monitoring and correction control of the product processing process is carried out according to the aligned processing order of the products and the effective waiting processing positions, so that when it is found that the product position or processing state deviates, correction can be carried out in time to ensure the accuracy and stability of the processing process. Through step S9, the motion monitoring and correction control method is supplemented and controlled according to the effectiveness of each waiting processing position and the rotation offset values of each product waiting for processing, so as to carry out supplementary control by combining the effectiveness of each waiting processing position and the rotation offset values of each product waiting for processing, and further improve the motion monitoring and correction control method. Description of the Drawings

[0040] Figure 1 This is a schematic flowchart of the flight vision laser processing method of this embodiment. Specific implementation manners

[0041] In order to make the objectives and advantages of the present invention clearer and more understandable, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0042] The preferred implementation manners of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these implementation manners are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0043] It should be noted that in the description of the present invention, the terms indicating directions or positional relationships such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings. This is only for convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as a limitation of the present invention.

[0044] In addition, it should also be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0045] Please refer to Figure 1 As shown, it is a schematic flowchart of the flight vision laser processing method of this embodiment, and the method includes:

[0046] Step S1, perform mapping correction on the vision camera to obtain the vision camera after mapping correction;

[0047] Step S2, after obtaining the vision camera after mapping correction, set key parameters and initialize the on-line laser processing device according to the key parameters to obtain the on-line laser processing device after initialization;

[0048] Step S3, run the on-line laser processing device after initialization to process the product, perform motion monitoring on the product processing process through the vision camera after mapping correction to obtain motion monitoring photos and motion monitoring photo numbers, and perform motion monitoring on the product processing process through the laser control card to obtain the current assembly line position of the motion monitoring photos;

[0049] Step S4, calculate the waiting processing position based on the key parameters and the current pipeline position of the motion monitoring photo;

[0050] Step S5, obtain the number of products waiting for processing and the rotation offset values of each product waiting for processing according to the motion monitoring photo;

[0051] Step S6, align and sort the scanning order of the products waiting for processing and the rotation offset values of the products waiting for processing according to the pipeline direction to obtain the aligned processing order of the products;

[0052] Step S7, judge the validity of the waiting processing position according to the key parameters and the number of products waiting for processing to obtain the validity of each waiting processing position and the valid waiting processing positions;

[0053] Step S8, perform motion monitoring correction control on the product processing process according to the aligned processing order of the products and the valid waiting processing positions;

[0054] Step S9, perform supplementary control on the motion monitoring correction control method according to the validity of each waiting processing position and the rotation offset values of each product waiting for processing.

[0055] Specifically, the method is applied to the intelligent control terminal device of an online laser processing device with high precision and high beat, such as the intelligent control terminal device applied to PCB marking, precision component cutting, etc. By providing real-time feedback on the offset during the laser processing, dynamically optimizing the laser path, and alleviating the overload of the galvanometer during the processing, the online laser processing efficiency is improved. Among them, the method performs mapping correction on the vision camera through step S1 to obtain the vision camera after mapping correction, eliminating problems such as imaging distortion and position deviation, so that the image information obtained by the vision camera can more accurately reflect the position and state of the actual product, providing a reliable basis for subsequent motion monitoring and processing control based on the vision image, ensuring the accuracy of product position judgment during the processing, and thus improving the processing precision and product quality. The method initializes the online laser processing device through step S2 to obtain the online laser processing device after initialization, and the setting of key parameters can be based on different processing requirements and product characteristics. The method runs the initialized online laser processing device to process the product through step S3, so as to timely obtain the position and motion state information of the product during the processing, accurately track and identify the processing process of each product, and the motion monitoring based on the vision camera can realize the real-time monitoring of the product processing process, avoiding processing problems caused by untimely or inaccurate manual monitoring. The method calculates the waiting processing position according to the key parameters and the current pipeline position of the motion monitoring photo through step S4, so as to accurately calculate the position of the product waiting for processing, improve the accuracy and efficiency of processing, reduce the idle stroke during the processing, and thus improve the efficiency of online laser processing. The method obtains the number of products waiting for processing and the rotation offset value of each product waiting for processing according to the motion monitoring photo through step S5, reasonably adjusts the processing rhythm according to the number of products, and avoids low processing efficiency caused by unreasonable processing order. By obtaining this offset value and making corresponding adjustments, the accuracy of processing can be guaranteed, the scrap rate can be reduced, and the processing efficiency can be improved. The method aligns and sorts the scanning order of the products waiting for processing and the rotation offset value of the products waiting for processing according to the pipeline direction through step S6 to obtain the aligned processing order of the products, reducing the frequent turning and adjustment of the laser processing device during the processing, reducing the working load of the galvanometer, and alleviating the problem of galvanometer overload during the processing. The method judges the effectiveness of the waiting processing position according to the key parameters and the number of products waiting for processing through step S7, so as to avoid unnecessary attempts and processing of the laser processing device on invalid positions, reduce the waste of processing time, and thus further improve the processing efficiency. The method performs motion monitoring and correction control on the product processing process according to the aligned processing order of the products and the effective waiting processing positions through step S8, so as to facilitate timely correction when the product position or processing state deviates, ensuring the accuracy and stability of the processing process.The method supplements the motion monitoring and correction control method according to the effectiveness of each waiting processing position and the rotation offset value of each waiting processing product through step S9, so as to perform supplementary control by combining the effectiveness of each waiting processing position and the rotation offset value of each waiting processing product, and further improve the motion monitoring and correction control method.

[0056] Specifically, in step S1, when performing mapping correction on the vision camera, control the on-line laser processing device to process a set of solid circular dots at a preset fixed position on the calibration plate to obtain the processed calibration plate, and use the coordinate position information set of this set of solid circular dots as the actual dot position group. Use the vision camera to take a picture of the processed calibration plate to obtain a picture of the processed calibration plate, obtain the position information of each solid circular dot in the picture of the processed calibration plate, use the position information of each solid circular dot in the picture of the processed calibration plate as the ideal dot position group, calculate the distortion error between the actual dot position group and the ideal dot position group, generate mapping correction parameters according to the distortion error, and perform mapping correction on the vision camera according to the mapping correction parameters to obtain the vision camera after mapping correction.

[0057] Specifically, the calibration plate refers to a processed plate with preset fixed positions calibrated. The preset fixed positions refer to the known positions pre-set by the administrator on the calibration plate. The administrator refers to the person responsible for the mapping correction of the vision camera, such as the team leader of the laser processing workshop. In this embodiment, the setting method of the preset fixed positions is not limited. Those skilled in the art can freely set according to the actual situation, as long as the pre-calibration requirements of the calibration plate are met. For example, it can be set that the administrator marks the positions of the solid round dot meshes to be laser processed on the calibration plate at intervals of 10 cm, controls the on-line laser processing device to process the positions of the solid round dot meshes to be laser processed, obtains the processed calibration plate, and inputs the position coordinates of the solid round dot meshes to be laser processed as the coordinate position information set of this group of solid round dot meshes into the intelligent control terminal device of the on-line laser processing device. The solid round dot meshes refer to the points on the processed calibration plate obtained after the on-line laser processing device processes the positions of the solid round dot meshes to be laser processed. The coordinate position information of the solid round dot meshes refers to the coordinate data obtained by inputting the position coordinates of the solid round dot meshes to be laser processed as the coordinate position information set of this group of solid round dot meshes into the intelligent control terminal device of the on-line laser processing device. The vision camera refers to the camera installed on the on-line laser processing device to photograph the processing process of the on-line laser processing device. In this embodiment, the model of the vision camera is not limited. Those skilled in the art can freely set according to the actual situation, as long as the requirement of photographing the processing process of the on-line laser processing device is met. In this embodiment, the processed calibration plate photo is obtained by uploading the processed calibration plate photo to the intelligent control terminal device of the on-line laser processing device through the vision camera. In this embodiment, the method for obtaining the positions of the solid round dot meshes in the processed calibration plate photo is not limited. Those skilled in the art can freely set according to the actual situation. For example, it can be set to obtain the positions of the solid round dot meshes in the processed calibration plate photo through image recognition technology. The distortion error refers to the average value of the position errors of the same solid round dot mesh in the actual mesh position group and the ideal mesh position group. For example, the actual mesh position group includes A1(xa1, ya1), A2(xa2, ya2), and A1(xa3, ya3). A1(xa1, ya1) represents the position coordinates of the first solid round dot mesh A1 on the processed calibration plate in the preset coordinate system, including the horizontal coordinate xa1 and the vertical coordinate ya1. A2(xa2, ya2) represents the position coordinates of the second solid round dot mesh A2 on the processed calibration plate in the preset coordinate system, including the horizontal coordinate xa2 and the vertical coordinate ya2. A3(xa3,ya3) represents the position coordinates of the third solid circular dot A3 on the calibrated plate after processing in the preset coordinate system, including the horizontal coordinate xa3 and the vertical coordinate ya3. The preset coordinate system takes the midpoint of the initial processing end of the calibrated plate as the origin, the pipeline direction as the x-axis, and the direction perpendicular to the pipeline direction as the y-axis. The ideal dot position group includes B1(xb1, yb1), B2(xb2, yb2), and B1(xb3, yb3). For the solid circular dots in the photo of the calibrated plate after processing, B1(xb1, yb1) represents the position coordinates of the first solid circular dot B1 in the photo of the calibrated plate after processing in the preset coordinate system, including the horizontal coordinate xb1 and the vertical coordinate yb1. B2(xb2, yb2) represents the position coordinates of the second solid circular dot B2 in the photo of the calibrated plate after processing in the preset coordinate system, including the horizontal coordinate xb2 and the vertical coordinate yb2. B3(xb3, yb3) represents the position coordinates of the third solid circular dot B3 in the photo of the calibrated plate after processing in the preset coordinate system, including the horizontal coordinate xb3 and the vertical coordinate yb3. The first solid circular dot A1 on the calibrated plate after processing and the first solid circular dot B1 in the photo of the calibrated plate after processing are the same solid circular dot. The second solid circular dot A2 on the calibrated plate after processing and the second solid circular dot B2 in the photo of the calibrated plate after processing are the same solid circular dot. The third solid circular dot A3 on the calibrated plate after processing and the third solid circular dot B3 in the photo of the calibrated plate after processing are the same solid circular dot. Calculate the distortion error r according to the actual dot position group and the ideal dot position group. Set:

[0058] , this embodiment does not limit the generation method of the mapping correction parameters. Those skilled in the art can freely set according to the actual situation, as long as the requirements for mapping correction of the vision camera are met. For example, it can be set to input the distortion error into the mapping correction expert database, obtain the preset distortion error with the smallest difference from the distortion error in the mapping correction expert database, and use the preset mapping correction parameter corresponding to the preset distortion error as the mapping correction parameter for generation. This embodiment does not specifically limit the method of mapping correction of the vision camera. Those skilled in the art can freely set according to the actual situation, as long as the requirements for mapping correction of the vision camera are met. For example, when the mapping correction parameter is a coordinate transformation matrix, the vision camera can be mapped and corrected according to the coordinate transformation matrix.

[0059] Specifically, in the step S2, when setting the key parameters, the key parameters include laser processing content, the maximum number of parts C1 processed in a single time, waiting distance D1, and interval distance D2. When setting the laser processing content, the processing pattern is obtained, and a processing path is generated according to the processing pattern. When setting the maximum number of parts C1 processed in a single time, the physical properties of the laser galvanometer in the online laser processing device are obtained, and the maximum number of parts C1 processed in a single time is set according to the physical properties of the laser galvanometer. When setting the waiting distance D1, the distance in the pipeline direction from the center of the vision camera to the center of the laser galvanometer is obtained and used as the waiting distance D1. When setting the interval distance D2, the size of the product to be processed is obtained, and the interval distance D2 is generated according to the size of the product to be processed;

[0060] In the step S2, when initializing the online laser processing device, the laser processing content, the maximum number of parts C1 processed in a single time, the waiting distance D1, and the interval distance D2 are input into the laser control card of the online laser processing device to obtain the initialized online laser processing device, and it is set that the initialized online laser processing device performs a forward scan along the pipeline direction during the product processing process.

[0061] Specifically, the laser processing content refers to the content that the online laser processing device will perform processing operations according to the technician's image. The processing pattern refers to the geometric pattern for laser processing, such as cutting contours, marking patterns, drilling positions, etc. In this embodiment, the method for obtaining the processing pattern is set to import the design file from CAD / CAM software. The processing path refers to the movement trajectory of the laser head during processing, which is converted from the geometric information of the processing pattern. In this embodiment, the method for generating the processing path according to the processing pattern is set to layer and optimize the CAD pattern to generate G-code and galvanometer control instructions. The maximum number of parts C1 processed in a single time refers to the upper limit of the number of parts that the laser galvanometer can stably process within a single trigger cycle. The physical properties of the laser galvanometer in the online laser processing device include the scanning range, dynamic response speed, and spot quality stability. The scanning range refers to the processing area that can be covered by the maximum deflection angle of the galvanometer. The dynamic response speed refers to the time required for the galvanometer to switch between different positions. The spot quality stability means that long-term continuous scanning may cause thermal drift or spot distortion, and C1 needs to be limited to ensure accuracy. In this embodiment, the method for obtaining the physical properties of the laser galvanometer in the online laser processing device is set to obtain through the galvanometer specification sheet. In this embodiment, the specific method for setting the maximum number of parts C1 processed in a single time according to the physical properties of the laser galvanometer is to combine the galvanometer performance and the part size, calculate the number of parts within the maximum area that can be covered by a single scan, and leave a certain safety margin, such as setting , Sa is the effective scanning range distance, Lc is the size of the product to be processed, Ac is the safety distance. The waiting distance D1 refers to the physical distance between the imaging center of the vision camera and the processing center of the laser galvanometer in the moving direction of the assembly line. In this embodiment, the method for obtaining the distance in the assembly line direction from the center of the vision camera to the center of the laser galvanometer is the mechanical measurement method, and an optical instrument is used to directly measure the installation distance between the camera and the galvanometer. The interval distance D2 refers to the minimum center distance between adjacent products to be processed on the assembly line. In this embodiment, the method for obtaining the size of the product to be processed is to directly read the CAD model. In this embodiment, the method for generating the interval distance D2 according to the size of the product to be processed is to add the safety distance required by the process, such as the anti-collision safety distance and the thermal influence zone safety distance, to the size of the product to be processed. The laser control card refers to the hardware core responsible for parsing the processing program (such as G code), coordinating the movement of the galvanometer and the laser output timing, and communicating with the PLC / vision system.

[0062] Specifically, in the step S3, when monitoring the movement during the product processing, the current assembly line moving distance Da is compared with the interval distance D2, and the photographing trigger result of the vision camera is judged according to the comparison result, where:

[0063] When Da < D2, it is determined that the photographing trigger result of the vision camera is not to trigger the vision camera to take a picture;

[0064] When Da = D2, it is determined that the photographing trigger result of the vision camera is to trigger the vision camera to take a picture, and an IO signal is sent through the laser control card to trigger the vision camera to take a picture, obtaining a motion monitoring photo, and numbering the motion monitoring photo to obtain the motion monitoring photo number M i , i is the number of times the vision camera takes pictures, i = 1, 2,..., n, n is an integer. At the same time, the encoder position of the current assembly line is marked through the laser control card to obtain the current assembly line position N of the motion monitoring photo i ;

[0065] When Da > D2, it is determined that the photographing trigger result of the vision camera is not to trigger the vision camera to take a picture, and the current assembly line moving distance Da is reset to zero, and the current assembly line moving distance Da is cumulatively calculated again starting from the current assembly line position of the current motion monitoring photo.

[0066] Specifically, the product processing process refers to the entire process of visual positioning and laser processing of the product to be processed by an on-line laser processing device. The current moving distance Da of the production line refers to the physical distance accumulated by the conveyor belt of the production line since the last trigger for taking a photo. In this embodiment, the current moving distance Da of the production line is calculated in real time through encoder pulse signals. The IO signal refers to the hardware control signal between the laser control card and the vision camera, which is used to accurately synchronize the photo-taking timing. The encoder position of the current production line refers to the real-time count value of the encoder at the moment of triggering the photo-taking, which is used to record the absolute position reference of the product to be processed on the production line.

[0067] Specifically, in step S4, when calculating the waiting processing position, according to the waiting distance D1 in the key parameters and the current position N of the production line in the motion monitoring photo i calculate the waiting processing position M i set M i = D1 + N i .

[0068] Specifically, the waiting processing position refers to the target processing position offset by the waiting distance D1 along the moving direction of the production line starting from the photo-taking trigger point of the vision camera.

[0069] Specifically, in step S5, when obtaining the number of products waiting to be processed, compare the waiting processing position M i with the current position N of the production line in the motion monitoring photo i and judge the current waiting processing position according to the comparison result, where:

[0070] When M i ≠ N i , it is determined that the waiting processing position is not the current waiting processing position, and the waiting processing position is not processed currently;

[0071] When M i = N i , it is determined that the waiting processing position is the current waiting processing position, and the waiting processing position is processed currently;

[0072] Obtain the waiting processing positions that have not been laser processed and their quantities in the current waiting processing positions. Take the waiting processing positions that have not been laser processed as the products waiting to be processed, and take the quantity of the waiting processing positions that have not been laser processed as the number H of products waiting to be processed.

[0073] Specifically, the current waiting processing position refers to the encoder feedback position updated in real time on the production line, that is, the physical position of the production line directly opposite the laser galvanometer at the current moment. The "not laser processed" means that the laser galvanometer has not performed processing yet.

[0074] Specifically, in the step S5, when obtaining the rotation offset values of each product to be processed, image recognition is performed on the motion monitoring photos to obtain the rotation offset values V of each product to be processed k , where k is the scanning order of the products to be processed, and k = 1, 2,... H

[0075] Specifically, the rotation offset value Vk of each product to be processed refers to the angular deviation of the product to be processed in the actual placement on the assembly line, relative to the theoretical position, that is, the rotation angle in the reference direction defined in the CAD model. In this embodiment, the means of image recognition of the motion monitoring photos is not limited, and those skilled in the art can freely set it according to the actual situation, as long as the recognition requirement of the rotation offset value is met. For example, the image recognition of the motion monitoring photos can be set by the template comparison method based on feature matching

[0076] Specifically, in the step S6, when aligning and sorting the scanning order of the products to be processed and the rotation offset values of the products to be processed, according to the assembly line direction, the scanning order k of the products to be processed and the rotation offset value V k are aligned and sorted to obtain the product alignment processing order Y, and Y is set as the order set in the form of k - V k , such as 1 - V1, 2 - V2,..., k - V k .

[0077] Specifically, in the step S7, when judging the effectiveness of the positions to be processed, the maximum number of parts C1 processed at one time in the key parameters is compared with the number of products H to be processed, and the effectiveness of the positions to be processed is judged according to the comparison result, where

[0078] When C1 ≥ H, it is determined that the positions to be processed corresponding to the number of products H to be processed that have not been laser processed are valid, and the positions to be processed corresponding to the number of products H to be processed that have not been laser processed are used as valid positions to be processed

[0079] When C1 < H, it is determined that the positions to be processed corresponding to the number of products to be processed within the maximum number of parts C1 processed at one time in the product alignment processing order and that have not been laser processed are valid, and the positions to be processed corresponding to the number of products to be processed within the maximum number of parts C1 processed at one time in the product alignment processing order and that have not been laser processed are used as valid positions to be processed. It is determined that the positions to be processed corresponding to the number of products to be processed outside the maximum number of parts C1 processed at one time in the product alignment processing order and that have not been laser processed are invalid

[0080] Specifically, in the step S8, when performing motion monitoring and correction control on the product processing process, the motion monitoring and correction control method is set as follows: retain the effective waiting processing positions in the product alignment processing sequence, and eliminate the unprocessed waiting processing positions that exceed the maximum number of processed parts C1 per single count in the product alignment processing sequence;

[0081] Transmit the motion monitoring and correction control method to the laser control card of the initialized online laser processing device.

[0082] Specifically, in the step S9, when performing supplementary control on the motion monitoring and correction control method, when the current position to be processed is an effective waiting processing position, obtain the waiting processing product rotation offset value V of the current position to be processed in the product alignment processing sequence k , compare it with each preset rotation offset value, and perform supplementary control on the motion monitoring and correction control method according to the comparison result, where:

[0083] When V k ≤V k1 , it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method, and the content of correcting the forward scan along the pipeline direction to reverse scan during the product processing is supplemented to the motion monitoring and correction control method;

[0084] When V k1 <V k <V k2 , it is determined that there are no processing hazards at the current position to be processed, and no supplementary control needs to be performed on the motion monitoring and correction control method;

[0085] When V k ≥V k2 , it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method, and the content of correcting the forward scan along the pipeline direction to reverse scan during the product processing is supplemented to the motion monitoring and correction control method;

[0086] V k1 is the first preset rotation offset value, set V k1 =-90°, V k2 is the second preset rotation offset value, set V k2 =90°.

[0087] Specifically, the forward scanning means that the galvanometer moves and scans synchronously along the moving direction of the production line, that is, the product transmission direction. If the production line moves from left to right (+X direction), the scanning path of the galvanometer is also processed row by row in the +X direction. The reverse scanning means that the galvanometer moves and scans along the opposite direction of the moving direction of the production line. If the production line moves from left to right (+X direction), the scanning path of the galvanometer is processed row by row in the -X direction.

[0088] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of the present invention.

Claims

1. A flight vision laser processing method, characterized in that Including: Step S1: Perform mapping correction on the vision camera to obtain the vision camera after mapping correction; Step S2: After obtaining the vision camera after mapping correction, set key parameters, and initialize the online laser processing device according to the key parameters to obtain the initialized online laser processing device; when setting the key parameters, the key parameters include laser processing content, the maximum number of parts processed per time C1, waiting distance D1, and interval distance D2; when setting the waiting distance D1, obtain the distance in the pipeline direction from the center of the vision camera to the center of the laser galvanometer and use it as the waiting distance D1, and when setting the interval distance D2, obtain the size of the product to be processed and generate the interval distance D2 according to the size of the product to be processed; Step S3: Run the initialized online laser processing device to process the product, perform motion monitoring on the product processing process through the vision camera after mapping correction to obtain motion monitoring photos and motion monitoring photo numbers, and perform motion monitoring on the product processing process through the laser control card to obtain the current pipeline position of the motion monitoring photos; when performing motion monitoring on the product processing process, compare the current pipeline movement distance Da with the interval distance D2, and judge the photo-taking trigger result of the vision camera according to the comparison result; Step S4, calculate the waiting processing position based on the key parameters and the current pipeline position in the motion monitoring photo; when calculating the waiting processing position, according to the waiting distance D1 in the key parameters and the current pipeline position N in the motion monitoring photo i calculate the waiting processing position M i set M i = D1 + N i ; Step S5: Obtain the number of products waiting to be processed and the rotation offset values of each product waiting to be processed according to the motion monitoring photos; Step S6: Align and sort the scanning order of the products waiting to be processed and the rotation offset values of the products waiting to be processed according to the pipeline direction to obtain the aligned processing order of the products; Step S7: Judge the effectiveness of the waiting processing positions according to the key parameters and the number of products waiting to be processed to obtain the effectiveness of each waiting processing position and the effective waiting processing positions; Step S8: Perform motion monitoring correction control on the product processing process according to the aligned processing order of the products and the effective waiting processing positions; Step S9: Perform supplementary control on the motion monitoring correction control method according to the effectiveness of each waiting processing position and the rotation offset values of each product waiting to be processed.

2. The flight vision laser processing method according to claim 1, characterized in that In the step S1, when performing mapping correction on the vision camera, control the online laser processing device to process a set of solid circular dot patterns at a preset fixed position on the calibration plate to obtain the processed calibration plate, and use the coordinate position information set of this set of solid circular dot patterns as the actual dot position group. Use the vision camera to take a photo of the processed calibration plate to obtain a photo of the processed calibration plate, obtain the position information of each solid circular dot pattern in the photo of the processed calibration plate, use the position information of each solid circular dot pattern in the photo of the processed calibration plate as the ideal dot position group, calculate the distortion error between the actual dot position group and the ideal dot position group, generate mapping correction parameters according to the distortion error, and perform mapping correction on the vision camera according to the mapping correction parameters to obtain the vision camera after mapping correction.

3. The flight vision laser processing method according to claim 2, characterized in that In the step S2, when setting the laser processing content, the processing pattern is obtained, and the processing path is generated according to the processing pattern. When setting the maximum number of parts C1 processed in one time, the physical properties of the laser galvanometer in the on-line laser processing device are obtained, and the maximum number of parts C1 processed in one time is set according to the physical properties of the laser galvanometer; In the step S2, when initializing the on-line laser processing device, the laser processing content, the maximum number of parts C1 processed in one time, the waiting distance D1, and the interval distance D2 are input into the laser control card of the on-line laser processing device to obtain the initialized on-line laser processing device, and it is set that the initialized on-line laser processing device scans forward along the assembly line direction during the product processing.

4. The flight vision laser processing method according to claim 3, characterized in that In the step S3, the triggering result of the visual camera is judged according to the comparison result, where: When Da < D2, it is determined that the triggering result of the visual camera is not to trigger the visual camera to take pictures; When Da = D2, it is determined that the photographing trigger result of the vision camera is to trigger the vision camera to take a picture. An IO signal is sent through the laser control card to trigger the vision camera to take a picture, obtaining a motion monitoring photo, and the motion monitoring photo is numbered to obtain the motion monitoring photo number M i , where i is the number of times the vision camera takes pictures, i = 1, 2,..., n, n is an integer. At the same time, the encoder position of the current production line is marked to obtain the current production line position N of the motion monitoring photo i ; When Da > D2, it is determined that the triggering result of the visual camera is not to trigger the visual camera to take pictures, and the current moving distance Da of the assembly line is reset to zero, and the current moving distance Da of the assembly line is accumulated again starting from the current position of the current motion monitoring photo.

5. The flight vision laser processing method according to claim 4, characterized in that, In step S5, when obtaining the number of products waiting to be processed, the waiting processing position M i is compared with the current assembly line position N i of the motion monitoring photo, and the current position to be processed is judged according to the comparison result, where: When M i ≠N i it is determined that the waiting processing position is not the current position to be processed, and the waiting processing position is not processed currently; When M i = N i it is determined that the waiting processing position is the current position to be processed, and currently process the waiting processing position; Obtain the waiting processing positions that have not been laser processed and their quantities in the current position to be processed, use the waiting processing positions that have not been laser processed as the waiting processing products, and use the quantity of the waiting processing positions that have not been laser processed as the quantity H of the waiting processing products; In step S5, when obtaining the rotation offset values of the products waiting for processing, image recognition is performed on the motion monitoring photos to obtain the rotation offset values V of the products waiting for processing k , where k is the scanning order of the products waiting for processing, and k = 1, 2,... H.

6. The flight vision laser processing method according to claim 5, characterized in that, In the step S6, when aligning and sorting the scanning order of the products to be processed and the rotation offset values of the products to be processed, the scanning order k of the products to be processed and the rotation offset value V of the products to be processed are aligned and sorted according to the pipeline direction k to obtain the aligned processing order Y of the products, and Y is set to k - V k which is a sequence set in data form.

7. The flight vision laser processing method according to claim 6, characterized in that, In the step S7, when judging the effectiveness of the waiting processing positions, the maximum number of parts C1 processed in one time in the key parameters is compared with the quantity H of the waiting processing products, and the effectiveness of the waiting processing positions is judged according to the comparison result, where: When C1 ≥ H, it is determined that the waiting processing positions that have not been laser processed corresponding to the quantity H of the waiting processing products are valid, and the waiting processing positions that have not been laser processed corresponding to the quantity H of the waiting processing products are used as the valid waiting processing positions; When C1 < H, it is determined that the waiting processing positions that have not been laser processed within the maximum number of parts C1 counted in the product alignment processing order are valid, and the waiting processing positions that have not been laser processed within the maximum number of parts C1 counted in the product alignment processing order are used as the valid waiting processing positions, and it is determined that the waiting processing positions that have not been laser processed outside the maximum number of parts C1 counted in the product alignment processing order are invalid.

8. The flight vision laser processing method according to claim 7, characterized in that, In the step S8, when performing motion monitoring and correction control on the product processing process, the motion monitoring and correction control method is set as: retaining the valid waiting processing positions in the product alignment processing order and excluding the waiting processing positions that have not been laser processed outside the maximum number of parts C1 counted in the product alignment processing order; The motion monitoring and correction control method is transmitted to the laser control card of the initialized on-line laser processing device.

9. The flight vision laser processing method according to claim 8, characterized in that, In step S9, when supplementing the control of the motion monitoring correction control method, when the current position to be processed is a valid waiting position for processing, obtain the waiting product rotation offset value V of the current position to be processed in the product alignment processing sequence k , compare it with each preset rotation offset value, and supplement the control of the motion monitoring correction control method according to the comparison result, where: When V k ≤ V k1 it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method. The content of correcting the forward scanning along the assembly line direction to reverse scanning during the product processing is supplemented to the motion monitoring and correction control method; When V k1 <V k <V k2 , it is determined that there are no processing hazards at the current position to be processed, and supplementary control of the motion monitoring and correction control method is not required; When V k ≥ V k2 it is determined that there are processing hazards at the current position to be processed, and supplementary control needs to be performed on the motion monitoring and correction control method. The content of correcting the forward scanning along the pipeline direction to reverse scanning during the product processing is supplemented to the motion monitoring and correction control method; V k1 is the first preset rotation offset value, set V k1 = -90°, V k2 is the second preset rotation offset value, set V k2 = 90°.

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