Laser displacement sensor with self-adaptive surface and processing method thereof

Abstract

The invention relates to a surface-adaptive laser displacement sensor and a processing method thereof, and relates to the technical field of sensors, the laser displacement sensor comprises a mechanical housing, the mechanical housing is internally provided with a light beam emitter, a photosensitive receiver, a signal processor and an output display, the signal processor comprises a signal feedback unit, a signal processing unit and a self-adaptive compensation unit; the photosensitive receiver, the signal processing unit and the output display are electrically connected in sequence; the photosensitive receiver, the signal feedback unit, the signal processing unit and the adaptive compensation unit are electrically connected in sequence. Through a closed-loop control system formed by the signal feedback unit, the signal processing unit and the self-adaptive compensation unit, the system parameters of the light beam emitter and the photosensitive receiver can be quickly responded and adjusted when the surface characteristics of the measured object change, so that error correction is carried out on the detection result, and the consistency and the stability of the measurement result are improved.

Description

Technical Field

[0001] This application relates to the technical field of sensors, and particularly to a laser displacement sensor with an adaptive surface and its processing method. Background Art

[0002] Laser displacement sensors are suitable for micron-level high-precision detection scenarios. Due to their non-contact, anti-interference, fast response, and high-precision characteristics, they are widely used in industrial inspection, industrial automation, precision measurement, scientific research instruments, intelligent sensing, machine vision, product quality inspection, and other fields.

[0003] Currently, existing laser displacement sensors mainly include a beam emitter, a photosensitive receiver, a signal processor, and an output display. The working principle of a laser displacement sensor is: beam emission, photosensitive reception, signal processing, and calculation output. Specifically: the beam emitter emits a beam towards the object to be measured. After the beam is diffusely reflected on the surface of the object to be measured, it is received by the photosensitive receiver. Inside the photosensitive receiver, the beam is imaged through a lens in the corresponding photosensitive reception area, and according to the different distances of the object to be measured, the position in the photosensitive reception area is different. Based on this principle, the signal processor processes the analog signal in the photosensitive area, calculates the actual distance of the object to be measured, and outputs and displays the calculated actual distance through the output display.

[0004] Based on the detection principle of the above laser displacement sensor, when the relative position between the object to be measured and the laser displacement sensor remains unchanged, the detection results of the laser displacement sensor should be the same. However, when the properties of the surface material, transparency, roughness, color, and surface treatment of the object to be measured change, the diffuse reflection characteristics of the beam will change accordingly, and then the optical signal received by the photosensitive receiver will also change accordingly, which will lead to inconsistent detection results. Summary of the Invention

[0005] This application provides a laser displacement sensor with an adaptive surface and its processing method, aiming to reduce the influence of changes in the surface properties of the object to be measured on the detection results of the laser displacement sensor and improve the stability and consistency of the detection results of the laser displacement sensor.

[0006] In a first aspect, a laser displacement sensor with an adaptive surface provided by the present application adopts the following technical solution: A laser displacement sensor with an adaptive surface includes a mechanical housing, and a beam emitter, a photosensitive receiver, a signal processor, and an output display are arranged inside the mechanical housing. The signal processor includes a signal feedback unit, a signal processing unit, and an adaptive compensation unit; the photosensitive receiver, the signal processing unit, and the output display are electrically connected in sequence. The signal processing unit is configured to receive and process the optical signal emitted by the photosensitive receiver and transmit the processed signal to the output display; the photosensitive receiver, the signal feedback unit, the signal processing unit, and the adaptive compensation unit are electrically connected in sequence. Both the beam emitter and the photosensitive receiver are electrically connected to the adaptive compensation unit. The signal feedback unit is configured to receive the optical signal emitted by the photosensitive receiver to calculate a feedback factor. The signal processing unit is configured to receive the feedback factor to calculate a compensation factor. The adaptive compensation unit is configured to receive the compensation factor to adjust the system parameters of the beam emitter and the photosensitive receiver.

[0007] By adopting the above technical solution, the beam emitter, the photosensitive receiver, the signal processor, and the output display arranged inside the mechanical housing work together to meet the functions of the laser displacement sensor and can realize the functions of laser ranging and display.

[0008] Through the cooperative setting of the signal feedback unit, the signal processing unit, and the adaptive compensation unit in the signal processor, the signal feedback unit calculates the feedback factor through the analysis of the optical signal emitted by the photosensitive receiver, so as to be able to sense the changes in the current measurement environment. The signal processing unit further uses the feedback factor to calculate the compensation factor, which can determine the compensation coefficient. The adaptive compensation unit can correspondingly adjust the system parameters of the beam emitter and the photosensitive receiver according to the compensation factor, so as to correct the measurement deviation in real time. Therefore, the setting of the signal processor introduces a closed-loop control in the laser displacement sensor, which enables the laser displacement sensor to actively correct the measurement result when the surface properties of the measured object change during laser ranging, improving the consistency and stability of the measurement result.

[0009] Optionally, it further includes an optical fixing base which is installed inside the mechanical housing. The beam emitter and the photosensitive receiver are both arranged on the optical fixing base, and the output display is arranged on one side of the mechanical housing. An optical cover plate is provided on the side of the mechanical housing facing away from the output display. The beam emitter and the photosensitive receiver both face the optical cover plate, and the beam can pass through the optical cover plate. The signal processor further includes a control circuit board, and the signal feedback unit, the signal processing unit, and the adaptive compensation unit are all integrated on the control circuit board. The beam emitter, the photosensitive receiver, and the output display are all electrically connected to the control circuit board.

[0010] By adopting the above technical solution, the optical fixing base is used to install the beam emitter and the photosensitive receiver, ensuring their stable positioning inside the mechanical housing. At the same time, the output display is placed on one side of the mechanical housing for easy observation of the laser ranging result. The optical cover plate is provided on the side of the mechanical housing facing away from the output display, enabling the beam to pass through smoothly, which ensures the normal operation of the laser displacement sensor. In addition, the signal processor includes a control circuit board, on which the signal feedback unit, the signal processing unit, and the adaptive compensation unit are integrated, which can simplify the circuit layout and improve the reliability.

[0011] Optionally, the beam emitter includes a laser tube and a laser circuit board. The laser tube is arranged on the laser circuit board, and the laser circuit board is electrically connected to the control circuit board. The laser circuit board is arranged on the optical fixing base, and a laser hole is provided on the optical fixing base. The laser tube is inserted and matched with the laser hole, and one end of the laser tube faces the optical cover plate. A laser adjustment threaded hole is provided on the optical fixing base, and the axial direction of the laser adjustment threaded hole is arranged along the corresponding radial direction of the laser hole. The laser adjustment threaded hole communicates with the laser hole, and the laser adjustment threaded hole is used to install an adjustment screw for adjusting the laser tube.

[0012] By adopting the above technical solution, the laser tube is arranged on the laser circuit board and inserted into the optical fixing base through the laser hole, realizing the installation of the beam emitter and ensuring the accuracy and stability of the optical path. At the same time, the electrical connection between the laser circuit board and the control circuit board enables the beam emitter to be adjusted in real time according to the adjustment index provided by the adaptive compensation unit, so as to better adapt to the influence brought by different surface characteristics. The design of the laser adjustment threaded hole allows for fine manual or automatic adjustment of the laser tube, further improving the directivity and focusing performance of the beam, and enhancing the adaptability and measurement accuracy of the sensor in complex measurement environments.

[0013] Optionally, a plurality of laser adjustment threaded holes are provided, and the plurality of laser adjustment threaded holes are sequentially arranged at intervals along the circumference of the laser hole.

[0014] By adopting the above technical solution, the multiple laser adjustment threaded holes are evenly distributed along the circumference of the laser hole. This design can finely adjust the laser lamp tube from multiple directions to ensure the collimation and positioning accuracy of the laser lamp tube.

[0015] Optionally, an aperture stop is provided on the optical fixing base. The aperture stop is inserted into the laser hole, and the aperture stop closes the laser hole; the aperture stop is coaxially arranged with the laser lamp tube, and the aperture stop is axially located between the laser lamp tube and the optical cover plate.

[0016] By adopting the above technical solution, the aperture stop is coaxially arranged with the laser lamp tube and closes the laser hole, ensuring that the emitted light beam maintains good collimation during propagation, reducing the influence of stray light, and thus improving the effective signal intensity and signal-to-noise ratio received by the photosensitive receiver. At the same time, the position of the aperture stop is set between the laser lamp tube and the optical cover plate, further optimizing the optical path structure, enabling the sensor to maintain stable measurement performance when facing different surface characteristics, and enhancing the robustness and reliability of the laser displacement sensor.

[0017] Optionally, a receiving lens and a reflecting mirror are provided on the optical fixing base. The receiving lens is located on the side of the optical fixing base facing the optical cover plate, and the receiving lens is used to receive the light beam diffusely reflected into the mechanical housing; the receiving lens, the reflecting mirror, and the photosensitive receiver are sequentially arranged, and the light beam passing through the receiving lens irradiates onto the reflecting mirror, and the light beam is reflected by the reflecting mirror onto the photosensitive receiver.

[0018] By adopting the above technical solution, the receiving lens can effectively collect the light beam diffusely reflected from the surface of the measured object and converge it onto the reflecting mirror. The reflecting mirror further guides the light beam to the photosensitive receiver to ensure that the optical signal can be accurately captured by the photosensitive receiver. This design of the optical path enhances the ability of the laser displacement sensor to collect weak optical signals and improves the detection accuracy and reliability.

[0019] Optionally, a filter is further provided on the optical fixing base. The filter is located between the receiving lens and the reflecting mirror, and the light beam between the receiving lens and the reflecting mirror passes through the filter.

[0020] By adopting the above technical solution, the filter is arranged between the receiving lens and the mirror, and can optimize and filter the light beam transmitted from the receiving lens. This helps to remove stray light and unnecessary wavelength components, making the optical signal finally reaching the photosensitive receiver purer, thereby improving the measurement accuracy and reliability.

[0021] In a second aspect, a processing method for a laser displacement sensor with an adaptive surface provided by the present application adopts the following technical solution: A processing method for a laser displacement sensor with an adaptive surface, which is used for the above laser displacement sensor, includes the following steps: S1. Laser ranging; S11. The beam emitter emits a light beam; S12. The photosensitive receiver receives the light beam, generates a corresponding optical signal, and transmits the optical signal to the signal processing unit; S13. The signal processing unit processes the optical signal and conveys the processed signal to the output display; S14. The output display shows the corresponding signal; S15. Repeat steps S11 - S14; S2. Feedback adjustment; S21. The photosensitive receiver transmits the optical signal to the signal feedback unit. The signal feedback unit calculates a comprehensive characteristic factor based on the optical signal, takes the difference between the current comprehensive characteristic factor and the comprehensive characteristic factor at the previous moment as the feedback factor at the current moment, and then inputs the feedback factor at the current moment into the signal processing unit; S22. The signal processing unit calculates the compensation factor at the current moment according to the feedback factor at the current moment and the feedback factor processing function, and inputs the compensation factor at the current moment into the adaptive compensation unit; S23. The adaptive compensation unit calculates the adjustment index according to the compensation factor at the current moment and the compensation factor conversion function; S24. The adaptive compensation unit adjusts the system parameters of the beam emitter and the photosensitive receiver according to the adjustment index so that the feedback factor at the next moment is equal to zero or approaches zero; S25. Repeat steps S21 - S24.

[0022] By adopting the above technical solution, in the laser ranging step, through the process of the beam emitter emitting a light beam, the photosensitive receiver receiving the light beam and generating an optical signal, the signal processing unit processing the optical signal, and the output display showing the corresponding signal, the basic laser ranging function is realized.

[0023] In the feedback adjustment step, a signal feedback unit is introduced to calculate the feedback factor, which can capture the difference in the optical signal between the current moment and the previous moment, so as to quantitatively characterize the influence of the change on the surface of the measured object; based on the feedback factor, a compensation factor is calculated and further converted into an adjustment index, enabling the laser displacement sensor to have the ability of self-adjustment; the adaptive compensation unit adjusts the system parameters of the beam emitter and the photosensitive receiver in real time according to the adjustment index, effectively reducing the influence of the surface characteristic change on the measurement result, correcting the detection result, and improving the overall stability of the sensor.

[0024] The introduction of feedback adjustment in laser ranging forms a closed-loop control mechanism, ensuring continuous monitoring and correction of errors throughout the measurement process, and significantly improving the measurement accuracy and the consistency of the measurement results.

[0025] Optionally, step S1 and step S2 are carried out synchronously.

[0026] By adopting the above technical solution, step S1 and step S2 are carried out synchronously, which can continuously and actively correct errors during the laser ranging process, improving the measurement accuracy and the consistency of the measurement results.

[0027] Optionally, in step S21, the calculation formula of the feedback factor is: R(n) = Y(n) - Y(n - 1); where, R represents the feedback factor, Y represents the comprehensive characteristic factor, n represents the current moment, and n - 1 represents the previous moment.

[0028] By adopting the above technical solution, the calculation of the feedback factor can quantify the difference between the optical signals of the photosensitive receiver at the current moment and the previous moment. The specific expression form of this difference is the change value of the comprehensive characteristic factor, that is, the feedback factor, so as to provide a clear data basis for the subsequent calculation of the compensation factor. Further, this calculation method ensures the effectiveness of the feedback mechanism, improving the accuracy and sensitivity in the adaptive adjustment process. Finally, in the face of different surface characteristic changes, the sensor can more accurately capture the actual distance information, significantly improving the consistency and stability of the measurement results.

[0029] In summary, the present application includes at least one of the following beneficial technical effects: 1. By introducing a closed-loop control system formed by a signal feedback unit, a signal processing unit, and an adaptive compensation unit, it can quickly respond and adjust the system parameters of the beam emitter and the photosensitive receiver when the surface characteristics of the measured object change, and then correct the error of the detection result to ensure the consistency and stability of the measurement result.

[0030] 2. Through the structural design of the laser displacement sensor, the laser displacement sensor can accurately capture optical signals, optimize the quality of optical signals, and improve the accuracy of detection results.

[0031] 3. Through the coordinated design of the laser adjustment threaded hole and the aperture diaphragm, the light beam emitted by the laser lamp tube can be calibrated and adjusted, thereby improving the quality of the emitted light beam and further improving the accuracy of detection results. Description of the Drawings

[0032] Figure 1 is the overall structural schematic diagram of the laser displacement sensor of Embodiment 1 of the present application.

[0033] Figure 2 is the exploded structural schematic diagram of the laser displacement sensor of Embodiment 1 of the present application.

[0034] Figure 3 is the schematic diagram of the laser ranging principle of the laser displacement sensor of Embodiment 1 of the present application.

[0035] Figure 4 is the overall structural schematic diagram of the optical fixing seat of Embodiment 1 of the present application.

[0036] Figure 5 is the sectional structural schematic diagram of the optical fixing seat of Embodiment 1 of the present application.

[0037] Figure 6 is the schematic diagram of the feedback adjustment principle of the laser displacement sensor of Embodiment 1 of the present application.

[0038] Figure 7 is the overall structural schematic diagram of the laser displacement sensor of Embodiment 2 of the present application.

[0039] Figure 8 is the overall structural schematic diagram of the main sensor of Embodiment 2 of the present application.

[0040] Figure 9 is the sectional structural schematic diagram of the main sensor of Embodiment 2 of the present application.

[0041] Figure 10 is the overall structural schematic diagram of the main sensor and the secondary sensor of Embodiment 2 of the present application with another installation method.

[0042] In the figure, 1 is the mechanical housing; 11 is the optical fixing base; 111 is the laser hole; 112 is the laser adjustment threaded hole; 12 is the optical cover plate; 13 is the housing cover plate; 2 is the beam emitter; 21 is the laser circuit board; 22 is the laser lamp tube; 23 is the aperture diaphragm; 3 is the photosensitive receiver; 4 is the signal processor; 41 is the control circuit board; 42 is the signal feedback unit; 43 is the signal processing unit; 44 is the adaptive compensation unit; 5 is the output display; 51 is the display circuit board; 52 is the display cover plate; 53 is the light-transmitting film; 54 is the display diaphragm; 6 is the cable; 7 is the optical path mechanism; 71 is the receiving lens; 72 is the filter; 73 is the mirror; 100 is the main sensor; 200 is the secondary sensor; 300 is the communication line; 400 is the communication interface; 500 is the connection component; 510 is the first connecting piece; 511 is the first connecting plate; 512 is the first mounting plate; 513 is the first threaded hole; 514 is the first positioning hole; 515 is the first screw; 520 is the second connecting piece; 521 is the second connecting plate; 522 is the second mounting plate; 523 is the second threaded hole; 524 is the second positioning hole; 525 is the second screw; 530 is the fixing bolt; 540 is the first hole group; 541 is the first fixing hole; 550 is the second hole group; 551 is the second fixing hole. Specific embodiments

[0043] The following will further describe the present application in detail with reference to the Figure 1 - attached Figure 10 drawings.

[0044] Embodiment 1: A laser displacement sensor with an adaptive surface, referring to Figure 1 and Figure 2 , including a mechanical housing 1, a beam emitter 2, a photosensitive receiver 3, a signal processor 4, an output display 5 and a cable 6. An optical fixing base 11 is arranged inside the mechanical housing 1. Both the beam emitter 2 and the photosensitive receiver 3 are arranged on the optical fixing base 11. The output display 5 is arranged on the side wall of the mechanical housing 1. The signal processor 4 is arranged inside the mechanical housing 1. And the output display 5, the beam emitter 2 and the photosensitive receiver 3 are all electrically connected to the signal processor 4. The cable 6 is arranged on the mechanical housing 1 and is electrically connected to the signal processor 4.

[0045] Referring to Figure 3, when performing laser ranging, the beam emitter 2 emits a beam, which is emitted outside the mechanical housing 1; when the beam irradiates the surface of the object to be measured, the beam undergoes diffuse reflection, and at this time, there is a beam reflected into the mechanical housing 1 and then received by the photosensitive receiver 3. At this time, the photosensitive receiver 3 generates an optical signal; the photosensitive receiver 3 transmits the generated optical signal to the signal processor 4, and the signal processor 4 processes the optical signal; the processed signal is transmitted to the output display 5, and the output display 5 displays the corresponding data or information. This realizes the basic function of the laser displacement sensor.

[0046] Refer to Figure 1 and Figure 2 , on the upper side of the mechanical housing 1, there is a housing cover plate 13, on one side in the width direction, there is an optical cover plate 12, on the other side, it is connected to the output display 5, and both the housing cover plate 13 and the optical cover plate 12 enclose the mechanical housing 1.

[0047] Refer to Figure 1 and Figure 2 , on the optical cover plate 12, there are two transparent plates. One transparent plate is arranged opposite to the beam emitter 2, and the other transparent plate is arranged corresponding to the photosensitive receiver 3. The setting of the optical cover plate 12 ensures that the beam can pass through the optical cover plate 12, so that the beam emitter 2 can emit a beam and the photosensitive receiver 3 can receive the beam.

[0048] Refer to Figure 4 and Figure 5 , the beam emitter 2 includes a laser circuit board 21, a laser lamp tube 22, and an aperture diaphragm 23. On the optical fixing seat 11, there is a laser hole 111. The laser lamp tube 22 is coaxially inserted into the laser hole 111. The aperture diaphragm 23 is coaxially arranged with the laser lamp tube 22 and is inserted into the laser hole 111. The aperture diaphragm 23 closes the laser hole 111. One end of the laser lamp tube 22 is connected to the laser circuit board 21, and the other end is spaced from the aperture diaphragm 23. And the laser circuit board 21 is connected to the optical fixing seat 11.

[0049] The cooperation of the laser circuit board 21 and the laser lamp tube 22 ensures that a beam can be emitted, meeting the function of the beam emitter 2. And the setting of the aperture diaphragm 23 can effectively restrict the divergence angle of the beam, improving the quality and accuracy of the beam.

[0050] Refer to Figure 2 and Figure 5 , the laser lamp tube 22, the aperture diaphragm 23, and the optical cover plate 12 are arranged in sequence along the axial direction of the laser lamp tube 22. And one end of the laser lamp tube 22 is arranged opposite to the corresponding transparent plate, and the aperture diaphragm 23 is located between the laser lamp tube 22 and the optical cover plate 12 along its own axial direction. This ensures that the beam emitter 2 can emit the beam outside the mechanical housing 1.

[0051] Refer toFigure 4 and Figure 5 A plurality of laser adjustment threaded holes 112 are provided on the optical fixing seat 11. The plurality of laser adjustment threaded holes 112 are arranged in sequence and spaced apart along the circumference of the laser hole 111, and the plurality of laser adjustment threaded holes 112 are arranged circumferentially around the laser hole 111. The axial direction of the laser adjustment threaded hole 112 is arranged along the radial direction corresponding to the laser hole 111, and one end of the laser adjustment threaded hole 112 is connected to the laser hole 111.

[0052] When the light beam needs to be straightened and adjusted, a manual adjustment screw or an automatic adjustment screw is installed in the corresponding laser adjustment threaded hole 112. At this time, the adjustment screw is turned to move in the corresponding laser adjustment threaded hole 112, so that the adjustment screw can contact the side wall of the laser lamp tube 22, thereby achieving fine-tuning of the laser lamp tube 22 and further straightening and adjusting the light beam.

[0053] Reference Figure 2 and Figure 4 An optical path mechanism 7 is also provided on the optical fixing seat 11, and the optical path mechanism 7 includes a receiving lens 71, a filter 72 and a reflector 73. The receiving lens 71 is arranged on the side of the optical fixing seat 11 facing the optical cover 12, and the axial direction of the receiving lens 71 is inclined to the axial direction of the laser lamp tube 22. The receiving lens 71, the filter 72, the reflector 73 and the photosensitive receiver 3 are arranged in sequence, and the receiving lens 71 and the filter 72 are arranged directly opposite to each other.

[0054] When the light beam enters the mechanical housing 1, the light beam passes through the receiving lens 71 and the filter 72 in sequence and then irradiates the reflector 73, and the light beam is reflected by the reflector 73 and then irradiates the photosensitive receiver 3, so that the photosensitive receiver 3 can receive the light beam. In this process, the receiving lens 71 can effectively collect and converge the light beam, and the filter 72 can optimize and filter the light beam, which can improve the laser displacement sensor's ability to collect weak light signals and improve detection accuracy and reliability.

[0055] Reference Figure 2 The output display 5 includes a display circuit board 51, a display cover plate 52, a light-transmitting film 53 and a display film 54. The display circuit board 51, the display cover plate 52, the light-transmitting film 53 and the display film 54 are arranged in parallel, and the display circuit board 51, the display cover plate 52, the light-transmitting film 53 and the display film 54 are sequentially attached. The display film 54 is arranged on a side of the mechanical housing 1 away from the optical cover plate 12, and the display circuit board 51, the display cover plate 52 and the light-transmitting film 53 are all located inside the mechanical housing 1.

[0056] Reference Figure 2 and Figure 6, the signal processor 4 includes a control circuit board 41. The laser circuit board 21, the photosensitive receiver 3, the display circuit board 51, and the cable 6 are all electrically connected to the control circuit board 41. The control circuit board 41 is located between the outer shell cover plate 13 and the optical fixing seat 11, and a signal feedback unit 42, a signal processing unit 43, and an adaptive compensation unit 44 are integrated on the control circuit board 41.

[0057] Referring to Figure 3 , the photosensitive receiver 3, the signal processing unit 43, and the output display 5 are electrically connected in sequence.

[0058] The photosensitive receiver 3 transmits an optical signal to the signal processing unit 43. The signal processing unit 43 processes the optical signal and then conveys it to the output display 5, and the output display 5 displays the corresponding data. Therefore, the signal processing unit 43 satisfies the basic functions of the signal processor 4.

[0059] Referring to Figure 6 , the photosensitive receiver 3, the signal feedback unit 42, the signal processing unit 43, and the adaptive compensation unit 44 are electrically connected in sequence, and both the beam emitter 2 and the photosensitive receiver 3 are electrically connected to the adaptive compensation unit 44.

[0060] The photosensitive receiver 3 sends an optical signal to the signal feedback unit 42. The signal feedback unit 42 analyzes and calculates the feedback factor based on the optical signal. The signal processing unit 43 further calculates the compensation factor using the feedback factor. The adaptive compensation unit 44 adjusts the system parameters of the beam emitter 2 and the photosensitive receiver 3 according to the compensation factor, thereby real-time correcting the measurement deviation and improving the consistency and stability of the detection mechanism of the laser displacement sensor. Therefore, with the cooperation of the signal feedback unit 42, the signal processing unit 43, and the adaptive compensation unit 44, the signal processor 4 has a negative feedback adjustment function.

[0061] The implementation principle of the embodiment of the present application is as follows: When performing laser ranging, the beam emitter 2 emits a beam. After the beam irradiates the object to be measured, diffuse reflection occurs, and the photosensitive receiver 3 receives the beam after diffuse reflection to generate an optical signal, and transmits the optical signal to the signal processor 4. The signal processor 4 processes the optical signal and conveys it to the output display 5, and the output display 5 can display the corresponding data, which can read the actual distance of the corresponding object to be measured on the laser displacement sensor, thus satisfying the function of laser ranging.

[0062] During the process of laser ranging, the signal feedback unit 42, the signal processing unit 43, and the adaptive compensation unit 44 cooperate with each other. According to the optical signal received by the photosensitive receiver 3, feedback adjustment is performed on the beam emitter 2 and the photosensitive receiver 3, which enables the laser displacement sensor to perform self-adaptive adjustment, quickly respond to changes in the surface properties of the object to be measured, and makes the measurement results of the laser sensor stable, improving the consistency of the detection results.

[0063] This embodiment also discloses a processing method for a laser displacement sensor with an adaptive surface. Referring to Figure 3 and Figure 6 , it includes the following steps: S1. Laser ranging.

[0064] S11. Beam emission. A beam is emitted towards the object to be measured through the beam emitter 2.

[0065] S12. Photosensitive reception. After the beam irradiates the object to be measured, diffuse reflection occurs. The photosensitive receiver 3 receives the beam after diffuse reflection, generates a corresponding optical signal, and transmits the optical signal to the signal processor 4.

[0066] S13. Signal processing. The signal processor 4 processes the optical signal and conveys the processed signal to the output display 5.

[0067] Specifically, the signal processor 4 calculates the actual distance of the object to be measured based on the received optical signal and transmits the calculation result to the output display 5.

[0068] S14. Display output. The output display 5 displays the processed signal.

[0069] Specifically, the output display 5 displays the actual distance of the object to be measured.

[0070] S15. Repeat steps S11 - S14.

[0071] S2. Feedback regulation.

[0072] S21. Signal feedback and feedback parameter calculation. In step S12, the photosensitive receiver 3 simultaneously transmits the optical signal to the signal processor 4 and the signal feedback unit 42. The signal feedback unit 42 calculates the comprehensive characteristic factor based on the received optical signal, takes the difference between the current comprehensive characteristic factor and the comprehensive characteristic factor at the previous moment as the feedback factor at the current moment, and then inputs the feedback factor at the current moment into the signal processing unit 43.

[0073] Specifically, the calculation formula for the feedback factor is: R(n) = Y(n) - Y(n - 1); where R represents the feedback factor, Y represents the comprehensive characteristic factor, n represents the current moment, and n - 1 represents the previous moment.

[0074] Among them, the comprehensive characteristic factor Y is calculated based on the optical signal, which represents the quantization index of the optical signal. Specifically, the comprehensive characteristic factor Y can be calculated through one or a combination of the optical signal parameter combinations such as the optical intensity amplitude, time - domain waveform characteristics, frequency - domain energy distribution, and spot position of the optical signal received by the photosensitive receiver 3 in the laser displacement sensor.

[0075] Specifically, the following provides a calculation formula for the comprehensive characteristic factor Y: Since the detection principle of the laser displacement sensor is: the beam emitter emits a beam at a certain angle onto the surface of the object to be measured, the beam is reflected on the surface of the object to be measured, and the reflected light is received by the photosensitive receiver 3 (for example: a CCD linear camera). When the distance between the object to be measured and the laser displacement sensor is different, the imaging position of the reflected light on the photosensitive receiver 3 and the light intensity received by the photosensitive receiver 3 are also different.

[0076] Based on this principle, the comprehensive characteristic factor Y is related to the imaging position of the reflected light on the photosensitive receiver 3 and the light intensity received by the photosensitive receiver 3.

[0077] According to this principle, a calculation formula for the comprehensive characteristic factor Y is established: Among them, A(n) represents the amplitude of the optical signal received by the sensor at the current moment (such as the voltage peak value or the light intensity integral value). A0 represents the calibrated reference amplitude, usually the initial light intensity value of the sensor under the standard surface. Then represents the light intensity amplitude ratio, which directly reflects the change in the reflectivity of the surface of the object to be measured (such as the reflection difference between metal and plastic).

[0078] ΔP(n) represents the offset distance between the actual position and the calibrated position of the center of the light spot on the photosensitive receiver 3. P0 represents the calibrated displacement reference value, usually taking the resolution of the sensor. Then represents the light spot position offset, which is directly related to the actual displacement or tilt angle of the object to be measured.

[0079] ||F(n)||2 represents the frequency domain energy of the current optical signal, which is calculated by performing a fast Fourier transform on the received optical signal and then calculating its L2 norm (i.e., the square root of the sum of the squares of the frequency domain amplitudes). F0 represents the calibrated reference frequency domain energy, usually the initial frequency domain energy of the sensor under the standard surface. Then represents the frequency domain energy ratio. The frequency domain energy ratio reflects the light signal scattering characteristics (such as the high-frequency attenuation of transparent materials or the harmonic components of periodic surface structures), enhancing the adaptability to complex surfaces.

[0080] α, β, and γ represent weight coefficients, and the sum of α, β, and γ is 1. The specific results of α, β, and γ are automatically adjusted according to experimental calibration or according to the actual detection situation and different detection emphases.

[0081] S22, compensation parameter calculation. The signal processing unit 43 calculates the compensation factor at the current moment according to the feedback factor at the current moment and the feedback factor processing function, and then inputs the compensation factor at the current moment into the adaptive compensation unit 44.

[0082] Specifically, the calculation formula for the compensation factor is as follows: C(n) = F{R(n)}; Where C represents the compensation factor, R represents the feedback factor, n represents the current moment, F represents the feedback factor processing function, that is, the function of the compensation factor C with respect to the feedback factor R, and F is established by fitting according to actual tests.

[0083] S23. Adjustment parameter calculation. The adaptive compensation unit 44 calculates the adjustment index according to the compensation factor at the current moment and the compensation factor conversion function.

[0084] Specifically, the calculation formula for the adjustment index is as follows: A(n + 1) = T{C(n)}; Where A represents the adjustment index, C represents the compensation factor, n represents the current moment, n + 1 represents the next moment, T represents the compensation factor conversion function, that is, the function of the adjustment index A with respect to the compensation factor C, and T is established by fitting according to actual tests.

[0085] S24. Adjustment. The adaptive compensation unit 44 adjusts the system parameters of the beam emitter 2 and the photosensitive receiver 3 according to the adjustment index, so that the feedback factor at the next moment is equal to zero or approaches zero.

[0086] Specifically, the system parameters adjusted in the beam emitter 2 are mainly the beam intensity. The principle of beam intensity adjustment is: by controlling the drive current or pulse width on the laser circuit board 21, and then controlling the laser power to change the beam intensity. The system parameters adjusted in the photosensitive receiver 3 are mainly the reception sensitivity. The principle of reception sensitivity adjustment is: dynamically adjusting the gain or integration time of the photosensitive receiver 3, and then adjusting the gain to compensate for signal attenuation or signal overload. In addition, when the aperture stop 23 adopts an adaptive aperture stop 23 or a dynamic aperture stop 23, the system parameters adjusted in the beam emitter 2 can also include the opening degree of the aperture stop 23. The principle of aperture stop 23 opening degree adjustment is: automatically adjusting the opening degree of the aperture stop 23, controlling the effective diameter of the beam, and optimizing the matching of the incident energy and avoiding reflection characteristics.

[0087] S25. Repeat steps S21 - S24.

[0088] It should be noted that step S1 and step S2 are carried out synchronously.

[0089] The implementation principle of the embodiment of this application is: during the laser ranging process, a feedback adjustment step is introduced, which can achieve closed-loop control. When there are differences in the detection results of laser ranging, the feedback adjustment can correct the detection results, thereby improving the consistency and stability of the laser ranging results and reducing the problem of abnormal detection results caused by changes in the surface properties of the measured object.

[0090] Embodiment 2: A laser displacement sensor with an adaptive surface. Refer to Figure 7 In this embodiment, the difference from Embodiment 1 lies in the main sensor 100 and the auxiliary sensor 200. In this embodiment, both the main sensor 100 and the auxiliary sensor 200 have the same structure as the laser displacement sensor in Embodiment 1.

[0091] Refer to Figure 2 and Figure 7 A communication line 300 is provided between the main sensor 100 and the auxiliary sensor 200. Both ends of the communication line 300 are electrically connected to the control circuit board 41 in the main sensor 100 and the control circuit board 41 in the auxiliary sensor 200 respectively.

[0092] In this embodiment, refer to Figure 7 and Figure 8 A communication interface 400 is provided on the mechanical housing 1, and the communication interface 400 is electrically connected to the corresponding control circuit board 41. One end of the communication line 300 is in plug-in fit with the corresponding communication interface 400.

[0093] Refer to Figure 7 Under the combined action of the main sensor 100, the auxiliary sensor 200 and the communication line 300, both the main sensor 100 and the auxiliary sensor 200 independently perform laser ranging. When the main sensor 100 encounters a mirror surface or a total reflection surface or other interferences that cause the detection result to exceed the threshold, the main sensor 100 receives the signal of the auxiliary sensor 200 and takes the detection result of the auxiliary sensor 200 as the standard. During this process, the main sensor 100 eliminates the error through its own negative feedback adjustment until the detection result of the main sensor 100 returns to normal, which can prevent the single main sensor 100 from being damaged or temporarily failing to accurately detect the actual position of the object to be measured.

[0094] Moreover, the setting of the auxiliary sensor 200 provides sufficient time for the negative feedback adjustment of the main sensor 100, enabling the system parameters of the beam emitter 2 and the photosensitive receiver 3 in the main sensor 100 to be gradually adjusted until the main sensor 100 returns to normal, which can prevent the system parameters of the beam emitter 2 and the photosensitive receiver 3 in the main sensor 100 from mutating and causing damage to the main sensor 100.

[0095] In this embodiment, refer to Figure 8 A connection assembly 500 is provided on the mechanical housing 1. The connection assembly 500 includes a first connecting member 510 and a second connecting member 520. The first connecting member 510 and the second connecting member 520 are respectively arranged on the two side walls in the length direction of the mechanical housing 1.

[0096] Refer to Figure 8 and Figure 9, the first connecting member 510 includes a plurality of first connecting plates 511. The length direction of the first connecting plates 511 is arranged along the thickness direction of the mechanical housing 1. The plurality of first connecting plates 511 are arranged at intervals in sequence along their own width direction. The first connecting plates 511 are detachably connected to the corresponding side walls of the mechanical housing 1. Both ends of the first connecting plates 511 in the length direction are rotatably connected with first mounting plates 512, and first threaded holes 513 are formed through the first mounting plates 512.

[0097] Refer to Figure 8 and Figure 9 , the second connecting member 520 includes a plurality of second connecting plates 521. The length direction of the second connecting plates 521 is arranged along the thickness direction of the mechanical housing 1. The plurality of second connecting plates 521 are arranged at intervals in sequence along their own width direction. The second connecting plates 521 are detachably connected to the corresponding side walls of the mechanical housing 1. Both ends of the second connecting plates 521 in the length direction are rotatably connected with second mounting plates 522, and second threaded holes 523 are formed through the second mounting plates 522.

[0098] Refer to Figure 7 and Figure 9 , the main sensor 100 is connected to the auxiliary sensor 200 along its own length direction. The first threaded holes 513 on the main sensor 100 and the second threaded holes 523 on the auxiliary sensor 200 are arranged in one-to-one correspondence, and the first threaded holes 513 are directly opposite and communicated with the corresponding second threaded holes 523, and fixing bolts 530 are inserted into the corresponding first threaded holes 513 and second threaded holes 523.

[0099] Refer to Figure 7 and Figure 10 , with the cooperation of the connecting assembly 500, the detachable connection between the main sensor 100 and the auxiliary sensor 200 can be realized. Based on such a connection method, the main sensor 100 can also be stacked with the auxiliary sensor 200 along its own thickness direction, which enables the main sensor 100 and the auxiliary sensor 200 to have a variety of installation position relationships, thereby meeting the actual use requirements.

[0100] Refer to Figure 8 and Figure 9 , both the first connecting plates 511 and the second connecting plates 521 are slidably connected to the mechanical housing 1 along their own length directions. A plurality of first hole groups 540 are formed on one side wall of the mechanical housing 1 in the length direction, and a plurality of second hole groups 550 are formed on the other side wall. The first hole groups 540 and the first connecting plates 511 are arranged in one-to-one correspondence, and the second hole groups 550 and the second connecting plates 521 are arranged in one-to-one correspondence.

[0101] Refer to Figure 8 and Figure 9, a plurality of first positioning holes 514 are formed in the first connecting plate 511. The plurality of first positioning holes 514 are arranged at intervals in sequence along the length direction of the first connecting plate 511. The first hole group 540 includes a plurality of first fixing holes 541. The plurality of first fixing holes 541 are arranged in sequence along the length direction of the first connecting plate 511, and there is a first fixing hole 541 that is directly opposite and communicated with the first positioning hole 514. A first screw 515 is inserted into the first positioning hole 514, and the first screw 515 is inserted and matched with the corresponding first fixing hole 541.

[0102] Referring to Figure 8 and Figure 9 , a plurality of second positioning holes 524 are formed in the second connecting plate 521. The plurality of second positioning holes 524 are arranged at intervals in sequence along the length direction of the second connecting plate 521. The second hole group 550 includes a plurality of second fixing holes 551. The plurality of second fixing holes 551 are arranged in sequence along the length direction of the second connecting plate 521, and there is a second fixing hole 551 that is directly opposite and communicated with the second positioning hole 524. A second screw 525 is inserted into the second positioning hole 524, and the second screw 525 is inserted and matched with the corresponding second fixing hole 551.

[0103] Referring to Figure 8 and Figure 9 , due to the cooperative setting of the first positioning hole 514, the first fixing hole 541, the first screw 515, the second positioning hole 524, the second fixing hole 551 and the second screw 525, both the first connecting plate 511 and the second connecting plate 521 can move along their own length directions, which can change the positions of the first mounting plate 512 and the second mounting plate 522, which can change the mounting position relationship between the main sensor 100 and the auxiliary sensor 200, and further make the position relationship between the main sensor 100 and the auxiliary sensor 200 meet different requirements.

[0104] The implementation principle of the embodiment of the present application is as follows: The main sensor 100 and the auxiliary sensor 200 work independently of each other and perform laser ranging simultaneously to ensure the accuracy of the detection results. During this process, the main sensor 100 monitors its own detection results in real time. When the detection results exceed the threshold due to specular reflection, surface mutation and other interferences, the main sensor 100 synchronously obtains the detection results of the auxiliary sensor 200 through the communication line 300 and preferentially uses the data output of the auxiliary sensor 200 to ensure the display continuity; at the same time, based on the reference value provided by the auxiliary sensor 200, the main sensor 100 gradually adjusts its own parameters through an enhanced negative feedback mechanism to eliminate errors through progressive iteration until the detection results return to normal and switch back to the detection data of the main sensor 100 itself. The cooperation between the main sensor 100 and the auxiliary sensor 200 realizes the redundant design and intelligent switching mechanism of the dual sensors, significantly enhances the fault tolerance and anti-interference ability of the laser displacement sensor under complex surface properties and extreme environments, and realizes highly robust adaptive measurement.

[0105] The embodiments of this specific implementation manner are all preferred embodiments of this application, and do not limit the protection scope of this application accordingly. The same components are denoted by the same reference numerals. Therefore, all equivalent changes made according to the structure, shape, and principle of this application shall be covered within the protection scope of this application.

Claims

1. A laser displacement sensor with an adaptive surface, characterized in that, Comprising: A mechanical housing (1), within which a light beam emitter (2), a photosensitive receiver (3), a signal processor (4), and an output display (5) are provided. The signal processor (4) includes a signal feedback unit (42), a signal processing unit (43), and an adaptive compensation unit (44); The photosensitive receiver (3), the signal processing unit (43), and the output display (5) are electrically connected in sequence. The signal processing unit (43) is configured to receive and process the optical signal emitted by the photosensitive receiver (3), and transmit the processed signal to the output display (5); The photosensitive receiver (3), the signal feedback unit (42), the signal processing unit (43), and the adaptive compensation unit (44) are electrically connected in sequence. Both the light beam emitter (2) and the photosensitive receiver (3) are electrically connected to the adaptive compensation unit (44). The signal feedback unit (42) is configured to receive the optical signal emitted by the photosensitive receiver (3) to calculate a feedback factor. The signal processing unit (43) is configured to receive the feedback factor to calculate a compensation factor. The adaptive compensation unit (44) is configured to receive the compensation factor to adjust the system parameters of the light beam emitter (2) and the photosensitive receiver (3).

2. The laser displacement sensor with an adaptive surface according to claim 1, characterized in that, It further includes an optical fixing base (11), which is installed within the mechanical housing (1). Both the light beam emitter (2) and the photosensitive receiver (3) are provided on the optical fixing base (11), and the output display (5) is provided on one side of the mechanical housing (1); An optical cover plate (12) is provided on the side of the mechanical housing (1) facing away from the output display (5). Both the light beam emitter (2) and the photosensitive receiver (3) are arranged facing the optical cover plate (12), and the light beam can pass through the optical cover plate (12); The signal processor (4) further includes a control circuit board (41), and the signal feedback unit (42), the signal processing unit (43), and the adaptive compensation unit (44) are all integrated on the control circuit board (41). Both the light beam emitter (2), the photosensitive receiver (3), and the output display (5) are electrically connected to the control circuit board (41).

3. The laser displacement sensor with an adaptive surface according to claim 2, characterized in that, The light beam emitter (2) includes a laser lamp tube (22) and a laser circuit board (21). The laser lamp tube (22) is provided on the laser circuit board (21), and the laser circuit board (21) is electrically connected to the control circuit board (41); The laser circuit board (21) is provided on the optical fixing base (11). A laser hole (111) is formed on the optical fixing base (11). The laser lamp tube (22) is in plug-in fit with the laser hole (111), and one end of the laser lamp tube (22) is arranged facing the optical cover plate (12); The optical fixing base (11) is provided with a laser adjustment threaded hole (112), the axial direction of the laser adjustment threaded hole (112) is arranged along the corresponding radial direction of the laser hole (111), the laser adjustment threaded hole (112) communicates with the laser hole (111), and the laser adjustment threaded hole (112) is used for installing an adjustment screw for adjusting the laser lamp tube (22).

4. The laser displacement sensor with an adaptive surface according to claim 3, characterized in that, A plurality of the laser adjustment threaded holes (112) are provided, and the plurality of laser adjustment threaded holes (112) are sequentially arranged at intervals along the circumferential direction of the laser hole (111).

5. The laser displacement sensor with an adaptive surface according to claim 3, characterized in that, An aperture diaphragm (23) is arranged on the optical fixing base (11), the aperture diaphragm (23) is inserted into the laser hole (111), and the aperture diaphragm (23) closes the laser hole (111); The aperture diaphragm (23) is coaxially arranged with the laser lamp tube (22), and the aperture diaphragm (23) is axially located between the laser lamp tube (22) and the optical cover plate (12).

6. The laser displacement sensor with an adaptive surface according to claim 2, characterized in that, A receiving lens (71) and a reflecting mirror (73) are arranged on the optical fixing base (11), the receiving lens (71) is located on the side of the optical fixing base (11) facing the optical cover plate (12), and the receiving lens (71) is used for receiving the light beam diffusely reflected into the mechanical housing (1); The receiving lens (71), the reflecting mirror (73) and the photosensitive receiver (3) are arranged in sequence, and the light beam passing through the receiving lens (71) irradiates on the reflecting mirror (73), and the light beam is reflected by the reflecting mirror (73) to the photosensitive receiver (3).

7. The laser displacement sensor with an adaptive surface according to claim 6, characterized in that, A filter (72) is further arranged on the optical fixing base (11), the filter (72) is located between the receiving lens (71) and the reflecting mirror (73), and the light beam between the receiving lens (71) and the reflecting mirror (73) passes through the filter (72).

8. A processing method for a laser displacement sensor with an adaptive surface, which is used for the laser displacement sensor described in any one of the above claims 1-7, characterized in that, Comprising the following steps: S1. Laser ranging; S11. The beam emitter (2) emits a light beam; S12. The photosensitive receiver (3) receives the light beam, generates a corresponding optical signal, and transmits the optical signal to the signal processing unit (43); S13. The signal processing unit (43) processes the optical signal and conveys the processed signal to the output display (5); S14. The output display (5) displays the corresponding signal; S15. Repeat steps S11 - S14; S2. Feedback adjustment; S21. The photosensitive receiver (3) transmits the optical signal to the signal feedback unit (42), the signal feedback unit (42) calculates a comprehensive characteristic factor according to the optical signal, takes the difference between the current comprehensive characteristic factor and the comprehensive characteristic factor at the previous moment as the feedback factor at the current moment, and then inputs the feedback factor at the current moment into the signal processing unit (43); S22. The signal processing unit (43) calculates the compensation factor at the current moment according to the feedback factor at the current moment and the feedback factor processing function, and inputs the compensation factor at the current moment into the adaptive compensation unit (44); S23. The adaptive compensation unit (44) calculates an adjustment index according to the compensation factor at the current moment and the compensation factor conversion function; S24. The adaptive compensation unit (44) adjusts the system parameters of the beam emitter (2) and the photosensitive receiver (3) according to the adjustment index, so that the feedback factor at the next moment is equal to zero or approaches zero; S25. Repeat steps S21 - S24.

9. A processing method of a laser displacement sensor with an adaptive surface according to claim 8, wherein: Step S1 and step S2 are carried out synchronously.

10. A processing method of a laser displacement sensor with an adaptive surface according to claim 8, wherein: In step S21, the calculation formula of the feedback factor is: R(n) = Y(n) - Y(n - 1); wherein, R represents the feedback factor, Y represents the comprehensive feature factor, n represents the current moment, and n - 1 represents the previous moment.

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