Laser processing controller, processing system and processing control method

Abstract

The invention discloses a laser processing controller, a processing system and a processing control method.The laser processing controller comprises a digital processing module, an EtherNET interface, an EtherCAT IN interface and an EtherCAT OUT interface, the EtherNET interface is connected with the digital processing module, the EtherCAT IN interface and the EtherCAT OUT interface are connected with the digital processing module, the EtherCAT IN interface is used for receiving state data of slave station equipment in an EtherCAT network, and the EtherCAT OUT interface is used for receiving the state data of the slave station equipment in the EtherCAT network; the EtherCAT OUT interface is used for transmitting a control instruction of the digital processing module to the EtherCAT slave station equipment; the galvanometer interface is connected with the digital processing module, and the galvanometer interface is used for converting the control instruction of the digital processing module into galvanometer parameters conforming to a galvanometer standard protocol and transmitting the galvanometer parameters to a galvanometer; and the laser device interface is connected with the digital processing module, and the laser device interface is used for converting the control instruction of the digital processing module into laser parameters and transmitting the laser parameters to a laser device. The synchronous precision and compatibility of multiple devices are improved, the machining precision and efficiency are improved, the limitation of a traditional system is solved, and the high-precision machining requirement is met.

Description

Technical Field

[0001] The present invention belongs to the technical field of laser processing, and in particular relates to a laser processing controller, a processing system and a processing control method. Background Art

[0002] Existing laser marking control cards have limitations in communication and system integration. These control cards typically use a dedicated pulse interface to communicate with the motion axis module, resulting in complex wiring and susceptibility to electromagnetic interference in industrial environments, impacting system stability and reliability. Furthermore, the lack of a unified communication protocol makes it difficult to effectively integrate existing control cards with other equipment in modern automated production lines (such as servo motors and sensors), limiting system scalability and flexibility. These issues not only impact laser processing accuracy and efficiency but also restrict the application of laser technology in a wider range of fields.

[0003] As a high-performance industrial Ethernet technology, EtherCAT offers advantages such as high-speed communication, high-precision synchronization, and flexible topology. It supports high-speed data transmission and achieves nanosecond-level synchronization control, making it ideally suited for laser processing applications requiring precise synchronization. EtherCAT's open standards and excellent compatibility facilitate integration with other industrial automation equipment, providing a technical foundation for upgrading laser processing systems. With the widespread adoption of EtherCAT in industrial control, its application in laser processing is becoming increasingly important.

[0004] Despite the significant advantages of the EtherCAT protocol, existing laser marking control cards haven't fully leveraged these advantages. These control cards face performance bottlenecks when handling complex laser processing tasks, making it difficult to achieve close coordination and efficient linkage between the motion axes, galvanometers, and lasers. Furthermore, existing systems suffer from insufficient communication stability and are susceptible to electromagnetic interference in industrial environments, compromising processing accuracy and efficiency. Summary of the Invention

[0005] The object of the present invention is to provide a laser processing system and a control method, which can solve the technical problems of poor linkage, low processing accuracy and processing efficiency existing in the prior art.

[0006] In order to achieve the above-mentioned object, a specific embodiment of the present invention provides a laser processing controller, wherein the laser processing controller includes: Digital processing module, used to process target graphic data information from the host computer software and convert it into control instructions; An Ethernet interface connected to the digital processing module, the Ethernet interface being used to receive target graphic data information sent by the host computer software; An EtherCAT IN interface and an EtherCAT OUT interface, each connected to the digital processing module, wherein the EtherCAT IN interface is used to receive status data of a slave device in the EtherCAT network, and the EtherCAT OUT interface is used to transmit control instructions of the digital processing module to the EtherCAT slave device to achieve control; A galvanometer interface, connected to the digital processing module, for converting control instructions from the digital processing module into galvanometer parameters that comply with a galvanometer standard protocol and transmitting the parameters to the galvanometer; The laser interface is connected to the digital processing module and is used to convert the control instructions of the digital processing module into laser parameters and transmit them to the laser.

[0007] In one or more embodiments of the present invention, the laser processing controller further includes a cache module, one end of which is connected to the digital processing module, and the cache module is used to temporarily store control instructions generated after processing by the digital processing module, wherein the control parameters include axis control instructions, laser instructions, and galvanometer instructions; The other end of the cache module is connected to the EtherCAT OUT interface, the galvanometer interface and the laser interface respectively, and the corresponding control instructions are transmitted to the corresponding interface, which is converted into control signals that comply with the protocol.

[0008] In one or more embodiments of the present invention, the laser processing controller further includes a power supply interface, an IO interface, and an axis encoder interface, wherein: The power interface is connected to an external power supply circuit, which is used to provide working power to the digital processing module, communication interface and various functional modules of the laser processing controller; The IO interface is used to connect external devices to facilitate the interaction of digital input signals and digital output signals between the laser processing controller and the external devices; The shaft encoder interface is used to connect to the motor encoder of the motion shaft, and the shaft encoder interface is used to receive status data of the motor.

[0009] In one or more embodiments of the present invention, the galvanometer interface includes an XY2-100 galvanometer interface, an SL2-100 galvanometer interface, an SPI galvanometer interface, a CTI-RAYLASE galvanometer interface, and a CANON galvanometer interface.

[0010] In another aspect of the present invention, a laser processing system is provided, comprising the laser processing controller described above, the laser processing system further comprising a host computer, a five-axis driver, a five-axis platform, a galvanometer, a laser, and peripheral equipment, wherein: The host computer is bidirectionally connected to the EtherNET interface of the laser processing controller, and is used to send target graphic data information to the controller and receive device status data fed back by the controller; The five-axis driver is an EtherCAT slave station. The five-axis driver receives axis control instructions through the EtherCAT OUT interface of the laser processing controller and returns operation status data through the EtherCAT IN interface. The five-axis driver is also mechanically connected to the five-axis platform to drive its movement; The five-axis platform is used to realize X / Y / Z axis linear motion and A / C axis rotation motion; The galvanometer is connected to the galvanometer interface of the laser processing controller; The laser is connected via a laser interface of the laser processing controller; The peripheral device is connected to the IO interface of the laser processing controller; The shaft encoder is installed on the shaft end of the five-axis platform motor and is connected through the shaft encoder interface of the laser processing controller.

[0011] In one or more embodiments of the present invention, the host computer is a host computer having a motion control API, a galvanometer laser control API, and a linkage control API.

[0012] In another aspect of the present invention, a laser processing control method is provided, which is applied to the laser processing controller described above, comprising the following steps: S1. The host computer sends target graphic data information to the laser processing controller through the EtherNet interface; S2, the digital processing module uses a trajectory planning algorithm to decompose the target graphic data into motion axis trajectory instructions, galvanometer trajectory instructions and laser trigger instructions; S3, the cache module temporarily stores three types of instructions and outputs them to the EtherCAT OUT interface, galvanometer interface, and laser interface in nanosecond-level synchronization sequence; S4, EtherCAT OUT interface converts motion axis trajectory instructions into EtherCAT protocol signals to control the motion of the five-axis platform; The galvanometer interface converts the galvanometer trajectory instructions into galvanometer standard protocol parameters to control the galvanometer scanning; The laser interface converts the laser trigger instruction into laser parameters and controls the laser light emission; S5, the axis encoder interface receives the motor encoder feedback data of the motion axis in real time, and the digital processing module performs closed-loop deviation compensation on the motion axis trajectory command based on the feedback data.

[0013] In one or more embodiments of the present invention, the trajectory planning algorithm in step S2 includes: The target machining path is discretized into a set of feature points, and a spline curve interpolation algorithm is used to generate a parameterized curve; Calculate the curvature of each point on the parameterized curve, establish a mapping relationship between curvature and feed speed, and dynamically adjust the feed speed of each axis based on this mapping relationship; Perform acceleration continuous processing on adjacent trajectory segments to ensure the continuity of the first-order derivative of the velocity curve; Extract the target position sequence of the five-axis platform from the global coordinates of the parameterized curve, assign the displacement and velocity values ​​of each axis based on the kinematic model, and generate the motion axis trajectory instructions; A local coordinate system is established with the real-time position of the motion axis as the origin, the relative displacement of the curve is converted into the galvanometer deflection angle, and a trajectory instruction that conforms to the galvanometer protocol is generated; According to the trajectory curvature and synthesis speed, the preset process parameter table is queried, the laser power and frequency parameters are matched, and the laser trigger instructions bound to the axis trajectory and galvanometer trajectory timestamps are generated.

[0014] In one or more embodiments of the present invention, the control method further includes: While executing step S2, a mechanical structure error mapping table and a temperature-deformation regression model are established; During the execution of step S3, the error mapping table is queried according to the current position to obtain the position compensation value, and the thermal deformation compensation value is calculated according to the temperature sensor data and the regression model; The position compensation value and the thermal deformation compensation value are added to the control instruction output by the buffer module.

[0015] In one or more embodiments of the present invention, the control method further includes a real-time monitoring and feedback mechanism, which includes: The actual position, speed and temperature data of each axis and key components are collected through position, speed and temperature sensors and filtered; Calculate the deviation between the actual position and the target position. When the deviation exceeds the preset threshold, pause the current instruction. After performing error correction, use a smooth transition curve to resume motion. The shaft encoder interface is used to receive the motor status data.

[0016] Beneficial effects: Compared with the existing technology, the present invention adopts the EtherCAT interface to realize communication with the five-axis drive and other equipment, has high-speed data transmission capability and supports nanosecond-level synchronous control, solves the limitations of multi-axis linkage and high-speed data transmission caused by the existing control card's reliance on PCI, USB and other interfaces, and ensures that the motion axis, galvanometer and laser are highly coordinated.

[0017] The galvanometer interface covers various types and can be adapted to galvanometers of different brands. The host computer has multiple control APIs, which facilitates integration with various automation equipment. It overcomes the poor compatibility and expansion difficulties caused by inconsistent protocols of existing control cards and can adapt to the needs of different production environments.

[0018] By optimizing the motion trajectory through trajectory planning algorithms and combining real-time feedback from the shaft encoder with closed-loop deviation compensation, mechanical errors and motion deviations can be corrected. The EtherCAT interface has strong anti-electromagnetic interference capabilities, reducing the impact of industrial environmental interference on processing and solving the problems of low precision and insufficient stability in existing systems.

[0019] The digital processing module decomposes the graphic data into multiple types of instructions and outputs them synchronously through the cache module. Combined with the error compensation mechanism, it realizes the integrated linkage of the motion axis, galvanometer, and laser. Compared with the defect of existing control cards that are difficult to coordinate multiple devices, it greatly improves the processing efficiency of complex processing tasks and reduces the complexity of operation.

[0020] The laser processing system's components are connected via standardized interfaces, resulting in a clear structure and easy installation and maintenance. Peripheral devices can be flexibly connected via I / O interfaces, allowing for the addition or removal of equipment based on production needs, eliminating the complex integration and high maintenance costs associated with traditional systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments described in the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive effort.

[0022] Figure 1 A schematic diagram of a laser processing controller according to one embodiment of the present invention; Figure 2 This is an overall schematic diagram of a laser processing system in one embodiment of the present invention; Figure 3 A schematic diagram of a laser processing controller and a laser processing system in one embodiment of the present invention; Figure 4 A schematic diagram of a trajectory decomposition route in one embodiment of the present invention; Figure 5 Schematic diagram of a laser processing control method in one embodiment of the present invention (I) Figure 6 Schematic diagram (2) of a laser processing control method in one embodiment of the present invention; Figure 7 Flowchart of a laser processing control method according to one embodiment of the present invention. DETAILED DESCRIPTION

[0023] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0024] In response to the above technical issues, such as Figure 1 As shown, the present invention introduces a laser processing controller and a digital processing module for processing target graphic data information from the host computer software and converting it into control instructions; The EtherNET interface is connected to the digital processing module and is used to receive target graphic data information sent by the host computer software. The EtherCAT IN interface and EtherCAT OUT interface are respectively connected to the digital processing module. The EtherCAT IN interface is used to receive status data of slave devices in the EtherCAT network. The slave devices here include modules directly used to drive or control lasers, axis drivers and galvanometers, including five-axis drivers, laser control modules and galvanometer control modules. The EtherCAT OUT interface is used to transmit control instructions from the digital processing module to the EtherCAT slave device. The slave device here is a five-axis driver, which is then connected to the motion axis control input for axis motion control. The galvanometer interface is connected to the digital processing module and is used to convert the control instructions of the digital processing module into galvanometer parameters that comply with the galvanometer standard protocol and transmit them to the galvanometer. The laser interface is connected to the digital processing module and is used to convert the control instructions of the digital processing module into laser parameters and transmit them to the laser, so as to control laser connection, light on / off, frequency setting, energy regulation control, and PSO function. In this embodiment, the digital processing module may be a ZYNQ digital processing module.

[0025] In a further embodiment, the laser processing controller also includes a cache module, one end of which is connected to the digital processing module, and the cache module is used to temporarily store control instructions generated after processing by the digital processing module, and the control parameters include axis control instructions, laser instructions and galvanometer instructions; the other end of the cache module is respectively connected to the EtherCAT OUT interface, the galvanometer interface and the laser interface, and the corresponding control instructions are passed to the corresponding interface, which is converted by the interface into a control signal that complies with the protocol. This laser processing controller with an internally integrated cache module is suitable for laser processing scenarios with high data throughput.

[0026] In a further embodiment, it further includes a power supply interface, an IO interface and a shaft encoder interface, wherein, The power interface is connected to the external power supply circuit, which is used to provide working power for the digital processing module, communication interface and various functional modules of the laser processing controller; the IO interface is used to connect external devices for the interaction of digital input signals and digital output signals between the laser processing controller and the external devices; the shaft encoder interface is used to connect the motor encoder of the motion axis, and the shaft encoder interface is used to receive the status data of the motor.

[0027] In a further embodiment, the galvanometer interface includes an XY2-100 galvanometer interface, an SL2-100 galvanometer interface, an SPI galvanometer interface, a CTI-RAYLASE galvanometer interface, and a CANON galvanometer interface.

[0028] The present invention uses the laser processing controller as the master station hub to perform linked laser processing, and connects the linked laser control marking card through an EtherNet Ethernet cable. The laser control marking card has EtherCAT configuration and adopts a serial configuration mode. The laser control marking card master station is connected to the galvanometer slave station, motion axis slave station, laser and other equipment.

[0029] like Figures 2 and 3 As shown, the present invention also provides a laser processing system. In addition to the laser processing controller mentioned above, the laser processing system also includes a host computer, a five-axis driver, a five-axis platform, a galvanometer, a laser and peripheral equipment, wherein the host computer is bidirectionally connected to the EtherNET interface of the laser processing controller, and is used to send target graphic data information to the controller and receive device status data feedback from the controller; the five-axis driver is an EtherCAT slave station, and the five-axis driver receives axis control instructions through the EtherCAT OUT interface of the laser processing controller and returns operation status data through the EtherCAT IN interface. The five-axis driver is also mechanically connected to the five-axis platform to drive its movement; the five-axis platform is used to realize X / Y / Z axis linear motion and A / C axis rotational motion; the galvanometer is connected to the galvanometer interface of the laser processing controller; the laser is connected through the laser interface of the laser processing controller; the peripheral equipment is connected to the IO interface of the laser processing controller; the axis encoder is installed on the motor shaft end of the five-axis platform and is connected through the axis encoder interface of the laser processing controller.

[0030] The host computer is a host computer with motion control API, galvanometer laser control API and linkage control API.

[0031] The laser processing system is centered around a laser processing controller, with its components integrated through standardized interfaces. A bidirectional connection between the host computer and the controller's EtherNET interface enables the transmission of target graphics data and the reception of device status data, forming the system's primary information exchange channel. The five-axis drive, acting as an EtherCAT slave, connects to the controller's EtherCATOUT and EtherCATIN interfaces, respectively, to receive axis control commands and transmit operating status data. Mechanical connections then drive the five-axis platform.

[0032] The galvanometer and laser are connected to the controller's galvanometer and laser interfaces, respectively, receiving corresponding control commands to complete scanning and beam generation. Peripheral devices are connected to the controller via the I / O interface, enabling control of auxiliary functions and status feedback. A shaft encoder is mounted on the motor shaft of the five-axis platform and transmits motor status data to the controller via the controller's shaft encoder interface, providing the basis for closed-loop control. The target graphics data sent by the host computer is processed by the controller's digital processing module, which then generates control commands for the motion axes, galvanometer, and laser. These commands are temporarily stored in a cache module and output through the corresponding interfaces in a synchronized sequence, controlling the coordinated operation of various devices. Driven by a five-axis driver, the five-axis platform achieves linear motion along the X / Y / Z axes and rotational motion along the A / C axes, meeting the requirements of various processing positions. The galvanometer adjusts its scanning trajectory based on commands transmitted via the interface, while the laser adjusts its parameters accordingly. These three components work together to complete the machining operation. Feedback data from the axis encoders and various interfaces is received by the controller, and the digital processing module uses this data to perform closed-loop deviation compensation to ensure machining accuracy. Peripheral devices interact with the controller via the I / O interface, ensuring smooth machining and forming a complete closed-loop control loop for laser machining.

[0033] like Figures 4-7 As shown, the present invention also provides a laser processing control method, comprising the following steps: S1. The host computer sends target graphic data information to the laser processing controller through the EtherNet interface; S2, the digital processing module uses a trajectory planning algorithm to decompose the target graphic data into motion axis trajectory instructions, galvanometer trajectory instructions and laser trigger instructions; S3, the cache module temporarily stores three types of instructions and outputs them to the EtherCAT OUT interface, galvanometer interface, and laser interface in nanosecond-level synchronization sequence; S4, EtherCAT OUT interface converts motion axis trajectory instructions into EtherCAT protocol signals to control the motion of the five-axis platform; The galvanometer interface converts the galvanometer trajectory instructions into galvanometer standard protocol parameters to control the galvanometer scanning; The laser interface converts the laser trigger instruction into laser parameters and controls the laser light emission; S5, the axis encoder interface receives the motor encoder feedback data of the motion axis in real time, and the digital processing module performs closed-loop deviation compensation on the motion axis trajectory command based on the feedback data.

[0034] The operator (Actor), as the initiator of the operation, needs to prepare the original 3D processing graphics. This graphics contains the complete outline, dimensions, and other information required for subsequent laser processing, and is the data foundation for the entire processing process. The trajectory decomposition algorithm decomposes the complex 3D graphics information into three key trajectory types and corresponding parameters based on the processing requirements: Axis trajectory: Generates axis control parameters and outputs corresponding Axis XYZAC instructions, which are used to control the motion trajectory of the five-axis platform (realizing X / Y / Z axis linear motion and A / C axis rotational motion) and clarify the movement and rotation paths of each axis of the five-axis platform during the machining process.

[0035] Laser trajectory: Generates laser parameters and outputs Laser signal instructions to control the laser's light output state, such as laser power, frequency, pulse width, etc., to ensure that the laser output matches the processing requirements.

[0036] Galvo trajectory: Form galvo parameters and output Galvo XYZ instructions to direct the scanning trajectory of the galvo, allowing the galvo to accurately control the deflection and movement of the laser beam within the processing plane.

[0037] The Axis XYZAC instructions, Laser signal instructions, and Galvo XYZ instructions derived from trajectory decomposition are transmitted to the cache module for temporary storage. The cache module's function is to organize these instructions in a timed sequence, ensuring that the three types of instructions are subsequently output according to strict synchronization logic. This prevents misalignment between the five-axis platform movement, laser light emission, and galvanometer scanning caused by timing errors, which can affect machining accuracy and results.

[0038] The cache module converts the instructions into corresponding control signals and outputs them according to the set synchronization mechanism: Axis control signal: Axis XYZAC control signal is sent to the five-axis driver, driving the five-axis platform to move along the planned axis trajectory, and driving the workpiece to reach the appropriate processing position and posture.

[0039] Laser control signal: Laser signal control signal is transmitted to the laser, so that the laser outputs a laser beam that meets the power, frequency and other requirements at the corresponding time according to the laser parameters.

[0040] Galvo control signal: The Galvo XYZ control signal is transmitted to the galvanometer, allowing the galvanometer to accurately control the scanning path of the laser beam in the processing area according to the galvanometer trajectory.

[0041] Finally, through the coordinated action of the five-axis platform, laser, and galvanometer, the laser processing operation is completed according to the original 3D processing graphics, realizing precise engraving, cutting and other processing technologies for the workpiece.

[0042] In this embodiment, axis trajectory extraction involves directly extracting the global coordinates (X / Y / Z / A / C) of a parameterized curve. Using a kinematic model, the resulting velocity of the curve is assigned to each axis, generating motion instructions containing the displacement and velocity values ​​for each axis. For example, a 3D curve is sliced ​​into time, and the target position of a five-axis platform is calculated at each moment, forming a discrete point sequence for the axis trajectory. Galvanometer trajectory extraction: A local coordinate system is established with the current position of the axis trajectory as the origin. The relative displacement (Δx, Δy) of the parameterized curve in the local coordinate system is converted into the galvanometer deflection angle. For example, when the axis trajectory is positioned at (20, 0, 0, 0, 0), the subsequent 5mm local offset of the curve (Δx = 5mm, Δy = 5mm) corresponds to the galvanometer's X' and Y' axis scanning instructions. The protocol conversion module generates a voltage signal or pulse sequence that can be recognized by the galvanometer interface. Laser parameter extraction: Based on the trajectory curvature and the combined speed of the axis and galvanometer, laser parameters are automatically matched using preset process parameter tables, such as the "curvature-power" and "speed-frequency" mapping relationships. These parameters are bound to the timestamps of the axis and galvanometer trajectories to ensure that the three types of command parameters output at the same time match each other. The above decomposition process is completed by the dedicated logic unit of the digital processing module, which realizes the parallel calculation and caching of the three types of instructions through internal registers. Finally, in step S3, the output is synchronized with the nanosecond timing, forming a complete closed loop of "extraction-matching-synchronization". It can achieve accurate splitting of the trajectory without adding additional independent steps.

[0043] In a further embodiment, while step S2 "the digital processing module uses a trajectory planning algorithm to decompose the target graphic data" is being executed, the construction of the basic model for error compensation is synchronously started: The mechanical structure error mapping table is pre-calibrated and generated through a laser interferometer. It uses the absolute position (X / Y / Z / A / C) of the five-axis platform as an index to store compensation values ​​for mechanical clearance, lead screw pitch error, and other corresponding positions. For example, at X=100mm, the compensation is +0.002mm. The effective range is updated in real time along with the parameterized curve of trajectory planning. The temperature-deformation regression model is generated based on historical data of multiple temperature sensors installed on key components such as lead screws and guide rails. The model input is the current temperature value, and the output is the structural deformation amount at that temperature, such as Z-axis + 0.0015 mm. The model parameters are dynamically optimized with the processing time. During the step S3 "cache module temporarily stores instructions and synchronously outputs", the real-time superposition of compensation values and the output of instructions form a closed loop: When the cache module reads the target position of the shaft trajectory instruction (such as X = 100 mm, Y = 50 mm), it synchronously queries the error mapping table to obtain the position compensation value (X + 0.002 mm, Y - 0.001 mm); At the same time, the temperature-deformation regression model is called to calculate the thermal deformation compensation value (Z + 0.0015 mm) based on the 35°C data collected by the current temperature sensor; The above compensation values are superimposed on the original control instructions through the adder circuit of the digital processing module, and are output to each interface through the cache module, ensuring that the final executed instructions contain double correction of mechanical and thermal deformation.

[0044] In further embodiments, the embedding link of real-time monitoring and feedback mechanism runs through the whole process of step S4 "each interface executes control instructions" and step S5 "closed loop deviation compensation", forming a dynamic adjustment link: Data acquisition and filtering: during step S4 execution, the position sensor (shaft encoder) collects the actual position of each shaft at a frequency of 1 kHz, the speed sensor obtains the real-time speed of the motor, and the temperature sensor collects the temperature data of the lead screw and motor housing; these raw data are processed by Kalman filtering to filter out electromagnetic interference noise in the industrial environment (such as compressing the position data fluctuation range from ± 0.005 mm to ± 0.001 mm).

[0045] In further embodiments, in step S5, the digital processing module calculates the difference between the filtered actual position and the target position (such as target X = 100 mm, actual X = 99.995 mm, deviation - 0.005 mm); when the absolute value of the deviation exceeds the preset threshold (such as ± 0.003 mm), a pause signal is triggered immediately, and the cache module stops outputting new instructions. In further embodiments, error correction is achieved by calling the spline curve interpolation in the trajectory planning algorithm, generating a transition curve with the current actual position as the starting point and the original target trajectory as the ending point, ensuring that the acceleration increases linearly from 0 to the rated value and then linearly to 0 (such as 0→500 mm / s²→0) to avoid impact; the shaft encoder interface continuously receives motor state data until the deviation returns to the threshold, and then resumes normal instruction output.

[0046] The above mechanism cooperates with trajectory planning and error compensation, so that the whole control method is upgraded from "instruction output" to "output-monitoring-correction" dynamic closed loop, which significantly improves the stability of machining precision.

[0047] Those skilled in the art will appreciate that embodiments of the application can be supplied as methods, systems, or computer program products. Accordingly, the application can be embodied in the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the application can be embodied in the form of a computer program product on one or more computer-usable storage media (including, but not limited to, disk memory, CD-ROMs, optical storage media, etc.) having computer usable program code embodied therein.

[0048] The present application is described in reference to the flowchart and / or block diagrams of the method, apparatus (system) and computer program product according to the embodiments of the present application. It should be understood that each flow and / or block in the flowchart and / or block diagram, and the combination of flows and / or blocks in the flowchart and / or block diagram can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general purpose computer, a special purpose computer, an embedded processor, or other programmable data processing apparatus to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing apparatus produce the functions specified in the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram. Figure 1 one or more flows and / or blocks Figure 1 a system to perform the functions specified in the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram.

[0049] These computer program instructions can also be stored in a computer readable memory that can direct a computer or other programmable data processing apparatus to work in a specific manner, so that the instructions stored in the computer readable memory produce a manufactured product including an instruction system that implements the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram. Figure 1 one or more flows and / or blocks Figure 1 a system to perform the functions specified in the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram.

[0050] These computer program instructions can also be loaded onto a computer or other programmable data processing apparatus, so that a series of operation steps are performed on the computer or other programmable data processing apparatus to produce a computer implemented process, so that the instructions executed on the computer or other programmable data processing apparatus provide a process for implementing the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram. Figure 1 one or more flows and / or blocks Figure 1 a system to perform the functions specified in the flowchart and / or block diagram block or blocks of the flowchart and / or block diagram.

[0051] It will be obvious to a person skilled in the art that the application is not limited to the details of the foregoing exemplary embodiments and can be implemented in other concrete forms without departing from the spirit or essential characteristics of the application. The embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the application being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference signs in the claims should not be construed as limiting the claims concerned.

[0052] Furthermore, it should be understood that although the description is made on the basis of the embodiments, not every embodiment contains only one independent technical solution, and the description is made in this way only for the sake of clarity, and a person skilled in the art should consider the description as a whole, and the technical solutions in each embodiment can also be combined appropriately to form other embodiments that can be understood by a person skilled in the art.

Claims

1. A laser processing controller, characterized in that: The laser processing controller includes: Digital processing module, used to process target graphic data information from the host computer software and convert it into control instructions; An Ethernet interface connected to the digital processing module, the Ethernet interface being used to receive target graphic data information sent by the host computer software; An EtherCAT IN interface and an EtherCAT OUT interface, each connected to the digital processing module, wherein the EtherCAT IN interface is used to receive status data of a slave device in the EtherCAT network, and the EtherCAT OUT interface is used to transmit control instructions of the digital processing module to the EtherCAT slave device; A galvanometer interface, connected to the digital processing module, for converting control instructions from the digital processing module into galvanometer parameters that comply with a galvanometer standard protocol and transmitting the parameters to the galvanometer; The laser interface is connected to the digital processing module and is used to convert the control instructions of the digital processing module into laser parameters and transmit them to the laser.

2. A laser processing controller according to claim 1, characterized in that: The laser processing controller further includes a cache module, one end of which is connected to the digital processing module, and the cache module is used to temporarily store control instructions generated after processing by the digital processing module, wherein the control parameters include axis control instructions, laser instructions, and galvanometer instructions; The other end of the cache module is connected to the EtherCAT OUT interface, the galvanometer interface and the laser interface respectively, and the corresponding control instructions are transmitted to the corresponding interface, which is converted into control signals that comply with the protocol.

3. A laser processing controller according to claim 1, characterized in that: The laser processing controller also includes a power supply interface, an IO interface and an axis encoder interface, wherein: The power interface is connected to an external power supply circuit, which is used to provide working power to the digital processing module, communication interface and various functional modules of the laser processing controller; The IO interface is used to connect external devices to facilitate the interaction of digital input signals and digital output signals between the laser processing controller and the external devices; The shaft encoder interface is used to connect to the motor encoder of the motion shaft, and the shaft encoder interface is used to receive status data of the motor.

4. A laser processing controller according to claim 1, characterized in that: The galvanometer interface includes an XY2-100 galvanometer interface, an SL2-100 galvanometer interface, an SPI galvanometer interface, a CTI-RAYLASE galvanometer interface and a CANON galvanometer interface.

5. A laser processing system, comprising the laser processing controller according to any one of claims 1 to 4, characterized in that: The laser processing system also includes a host computer, a five-axis driver, a five-axis platform, a galvanometer, a laser and peripheral equipment, wherein: The host computer is bidirectionally connected to the EtherNET interface of the laser processing controller, and is used to send target graphic data information to the controller and receive device status data fed back by the controller; The five-axis driver is an EtherCAT slave station. The five-axis driver receives axis control instructions through the EtherCAT OUT interface of the laser processing controller and returns operation status data through the EtherCAT IN interface. The five-axis driver is also mechanically connected to the five-axis platform to drive its movement; The five-axis platform is used to realize X / Y / Z axis linear motion and A / C axis rotation motion; The galvanometer is connected to the galvanometer interface of the laser processing controller; The laser is connected via a laser interface of the laser processing controller; The peripheral device is connected to the IO interface of the laser processing controller; The shaft encoder is installed on the shaft end of the five-axis platform motor and is connected through the shaft encoder interface of the laser processing controller.

6. A laser processing system according to claim 5, characterized in that: The host computer is a host computer with motion control API, galvanometer laser control API and linkage control API.

7. A laser processing control method, characterized in that: The control method is applied to the laser processing controller according to any one of claims 1 to 4, comprising the following steps: S1. The host computer sends target graphic data information to the laser processing controller through the EtherNet interface; S2, the digital processing module uses a trajectory planning algorithm to decompose the target graphic data into motion axis trajectory instructions, galvanometer trajectory instructions and laser trigger instructions; S3, the cache module temporarily stores three types of instructions and outputs them to the EtherCAT OUT interface, galvanometer interface, and laser interface in nanosecond-level synchronization sequence; S4, EtherCAT OUT interface converts motion axis trajectory instructions into EtherCAT protocol signals to control the motion of the five-axis platform; The galvanometer interface converts the galvanometer trajectory instructions into galvanometer standard protocol parameters to control the galvanometer scanning; The laser interface converts the laser trigger instruction into laser parameters and controls the laser light emission; S5, the axis encoder interface receives the motor encoder feedback data of the motion axis in real time, and the digital processing module performs closed-loop deviation compensation on the motion axis trajectory command based on the feedback data.

8. The laser processing control method according to claim 7, characterized in that: The trajectory planning algorithm in step S2 includes: The target machining path is discretized into a set of feature points, and a spline curve interpolation algorithm is used to generate a parameterized curve; Calculate the curvature of each point on the parameterized curve, establish a mapping relationship between curvature and feed speed, and dynamically adjust the feed speed of each axis based on this mapping relationship; Perform acceleration continuous processing on adjacent trajectory segments to ensure the continuity of the first-order derivative of the velocity curve; Extract the target position sequence of the five-axis platform from the global coordinates of the parameterized curve, assign the displacement and velocity values ​​of each axis based on the kinematic model, and generate the motion axis trajectory instructions; A local coordinate system is established with the real-time position of the motion axis as the origin, the relative displacement of the curve is converted into the galvanometer deflection angle, and a trajectory instruction that conforms to the galvanometer protocol is generated; According to the trajectory curvature and synthesis speed, the preset process parameter table is queried, the laser power and frequency parameters are matched, and the laser trigger instructions bound to the axis trajectory and galvanometer trajectory timestamps are generated.

9. The laser processing control method according to claim 7, characterized in that: The control method further includes: While executing step S2, a mechanical structure error mapping table and a temperature-deformation regression model are established; During the execution of step S3, the error mapping table is queried according to the current position to obtain the position compensation value, and the thermal deformation compensation value is calculated according to the temperature sensor data and the regression model; The position compensation value and the thermal deformation compensation value are added to the control instruction output by the buffer module.

10. The laser processing control method according to claim 7, characterized in that: The control method also includes a real-time monitoring and feedback mechanism, which includes: The actual position, speed and temperature data of each axis and key components are collected through position, speed and temperature sensors and filtered; Calculate the deviation between the actual position and the target position. When the deviation exceeds the preset threshold, pause the current instruction. After performing error correction, use a smooth transition curve to resume motion. The shaft encoder interface is used to receive the motor status data.

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