Rapid calibration method for high-power laser galvanometer with OCT (Optical Coherence Tomography) function

Abstract

The method comprises the following steps that 1, a main controller enters a calibration mode; 2, controlling a galvanometer driving mechanism to lift a galvanometer to a safe height; 3, shooting the calibration test piece through a CCD recognition device; 4, controlling a galvanometer servo mechanism to move in the X, Y and Z directions; 5, the main controller judges the focus height by combining the OCT module detection signal; 6, after the focus height is judged to be qualified, the main controller sends a signal to a galvanometer software calibration module, and reference arm length calibration and optimal focal length optimization are executed; step 7, outputting an enable signal by the main controller; according to the rapid calibration method for the high-power laser galvanometer with the OCT function, after a new galvanometer is replaced or the galvanometer is maintained, rapid calibration response of the galvanometer is achieved, most manual operation in the calibration process is simplified into automatic operation, risks are avoided, and one-key calibration action during galvanometer calibration is achieved.

Description

Technical Field

[0001] This invention relates to a rapid calibration method for a high-power laser galvanometer, and particularly to a rapid calibration method for a high-power laser galvanometer with OCT function, belonging to the field of high-power laser galvanometer technology. Background Technology

[0002] For high-power laser welding galvanometers, during the calibration process after galvanometer replacement, the calibration stage (hereinafter referred to as the stage) used to place the calibration sample is first manually positioned within the galvanometer's extreme movement range. Then, the galvanometer is raised to a safe position along the Z-axis. Next, using a human-machine interface (e.g., a touchscreen or robotic pendant), the galvanometer is horizontally moved above the stage while maintaining a constant Z-axis height. The galvanometer's red light preview function is activated, and the galvanometer is slowly moved in multiple batches towards the center of the sample on the stage used for galvanometer calibration. Wait... After visually confirming that the red light spot of the galvanometer is centered on the test piece on the platform, manually turn off the red light preview function of the galvanometer. Use a tape measure or other measuring equipment to manually measure the actual height of the galvanometer in the Z direction from the test piece. When the actual height of the galvanometer in the Z direction from the black aluminum plate is different from the focal height, move the galvanometer closer to the test piece until the height matches the required focal height. Then, manually operate the software calibration module to first calibrate the reference arm length and find the optimal focal length. Then, manually control the laser output according to the on-site conditions, and control the software to identify the solder joint to complete the calibration.

[0003] The traditional calibration process for high-power galvanometers involves personnel controlling equipment step-by-step. During the calibration process, there is no communication between the various mechanisms. Multiple people control multiple mechanisms, making the process complex and unpredictable. Personnel are easily overwhelmed by the constant movement, leading to risks of collisions and personnel safety hazards. Furthermore, manual visual measurement of the focal point height is not accurate enough. Additionally, the calibration process involves step-by-step adjustments based on actual conditions, resulting in excessively long calibration times and severely impacting normal production line operations. Summary of the Invention

[0004] The purpose of this invention is to provide a rapid calibration method for a high-power laser galvanometer with OCT function, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a rapid calibration method for a high-power laser galvanometer with OCT function, comprising the following steps: Step 1: Select the galvanometer calibration function on the device's human-machine interface, and the main controller will enter calibration mode; Step 2: Control the galvanometer drive mechanism to raise the galvanometer to a safe height and move it along a preset trajectory above the fixed calibration stage; Step 3: Use a CCD recognition device to photograph the calibration test piece to confirm whether the galvanometer is centered on the test piece; Step 4: Control the galvanometer servo mechanism to move in the XYZ directions, use a laser rangefinder to detect the height distance between the galvanometer and the test piece, and feed the measurement result back to the main controller; Step 5: The main controller combines the detection signal from the OCT module to determine the focal height, and performs compensation control based on the detection result to ensure that the focal height meets the preset conditions; Step 6: After the focal height is determined to be qualified, the main controller sends a signal to the galvanometer software calibration module to perform reference arm length calibration and optimal focal length optimization. Step 7: The main controller outputs an enable signal to control the laser to emit light, and the software automatically identifies the solder joints to complete the calibration. Step 8: After calibration is completed, each mechanism resets according to the predetermined trajectory, and the main controller exits the calibration mode.

[0006] As a preferred embodiment of the present invention, the calibration platform is fixedly installed inside the equipment and is used to place black aluminum plates or perforated aluminum foil test pieces.

[0007] As a preferred embodiment of the present invention, the main controller is a PLC or a robot controller, used to detect the status of each mechanism of the equipment and control the operation of the galvanometer servo mechanism, CCD recognition device, laser rangefinder and OCT module.

[0008] As a preferred technical solution of the present invention, the CCD recognition method is based on any one of template matching, feature extraction or coordinate system transformation.

[0009] As a preferred embodiment of the present invention, the laser rangefinder is either a rangefinder integrated with the galvanometer or an external rangefinder mounted on the galvanometer field mirror or the galvanometer drive mechanism.

[0010] As a preferred embodiment of the present invention, the OCT module communicates with the main controller to output the focus height detection result, and the main controller performs automatic compensation control based on the detection result.

[0011] As a preferred technical solution of the present invention, during the calibration process, the main controller communicates in real time with the galvanometer software calibration module and the OCT module to automatically complete the reference arm length calibration and focal length optimization.

[0012] Compared with the prior art, the beneficial effects of the present invention are: The present invention provides a rapid calibration method for a high-power laser galvanometer with OCT function, which enables rapid calibration response of the galvanometer after replacement or repair. This approach simplifies most manual operations in the calibration process into automatic operations, avoids risks, and achieves one-click calibration during galvanometer calibration. Specific advantages include: 1. Reduce manpower required during the calibration process; what used to be a multi-person operation can now be simplified to a single-person operation. 2. Reduce the time required for galvanometer calibration and reduce downtime. 3. Enhance communication among various departments during calibration to reduce the risk of equipment collisions and personnel safety risks caused by operational errors during galvanometer calibration. Instead, replace the equipment with automatic modular operation based on preset programs. 4. To reduce the risk of visual error when measuring focal height during galvanometer calibration, the equipment automatically detects the focal height and implements compensation control based on the detected focal height. 5. Enhance communication between the main controller, OCT, and calibration software during the calibration process, and reduce manual operation of the software based on the field conditions during galvanometer calibration by automatically controlling the calibration based on the output signal. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0014] The technical solutions in the embodiments of the present invention have been clearly and completely described. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0015] Please see Figure 1 This invention provides a rapid calibration method for a high-power laser galvanometer with OCT function, comprising the following steps: Step 1: Select the galvanometer calibration function on the device's human-machine interface, and the main controller will enter calibration mode; Step 2: Control the galvanometer drive mechanism to raise the galvanometer to a safe height and move it along a preset trajectory above the fixed calibration stage; Step 3: Use a CCD recognition device to photograph the calibration test piece to confirm whether the galvanometer is centered on the test piece; Step 4: Control the galvanometer servo mechanism to move in the XYZ directions, use a laser rangefinder to detect the height distance between the galvanometer and the test piece, and feed the measurement result back to the main controller; Step 5: The main controller combines the detection signal from the OCT module to determine the focal height, and performs compensation control based on the detection result to ensure that the focal height meets the preset conditions; Step 6: After the focal height is determined to be qualified, the main controller sends a signal to the galvanometer software calibration module to perform reference arm length calibration and optimal focal length optimization. Step 7: The main controller outputs an enable signal to control the laser to emit light, and the software automatically identifies the solder joints to complete the calibration. Step 8: After calibration is completed, each mechanism resets according to the predetermined trajectory, and the main controller exits the calibration mode.

[0016] The calibration platform is fixedly installed inside the equipment and is used to place black aluminum plates or perforated aluminum foil test pieces.

[0017] Furthermore, the main controller is a PLC or a robot controller, used to detect the status of each mechanism of the equipment and control the operation of the galvanometer servo mechanism, CCD recognition device, laser rangefinder and OCT module.

[0018] Preferably, the CCD recognition method is based on any one of template matching, feature extraction, or coordinate system transformation.

[0019] The laser rangefinder is either a rangefinder integrated into the galvanometer or an external rangefinder mounted on the galvanometer field lens or the galvanometer drive mechanism.

[0020] Furthermore, the OCT module communicates with the main controller to output the focus height detection result, and the main controller performs automatic compensation control based on the detection result.

[0021] During the calibration process, the main controller communicates in real time with the galvanometer software calibration module and the OCT module to automatically complete the reference arm length calibration and focal length optimization.

[0022] In practical use, this invention provides a rapid calibration method for a high-power laser galvanometer with OCT function. 1. Add a dedicated calibration platform. The calibration platform is fixedly installed inside the equipment at a certain location. The platform is used to place calibration test pieces. When the operator activates the galvanometer calibration function on the host computer's manual interface, the equipment enters the galvanometer calibration state. The galvanometer calibration function can be implemented on the host computer via a touch screen, industrial control computer software soft start, or hard start via a master button, etc. The test piece can be a black aluminum plate or a perforated aluminum foil. 2. The main program of the equipment detects the status of each mechanism and component of the equipment, detects and eliminates any conditions that may affect the calibration of the galvanometer standard. The main program is stored inside the main controller, which can be a PLC or a robot controller, etc. 3. The galvanometer mechanism automatically raises the galvanometer to a safe height according to the received signal. The mechanism that drives the galvanometer height can be a servo control or a robotic arm. 4. The galvanometer mechanism moves to the center of the calibration black aluminum plate according to the preset path. Whether the movement is in place is confirmed by CCD image recognition. CCD image recognition can adopt recognition mode based on template matching, recognition mode based on feature extraction, or recognition mode based on coordinate system transformation, etc. 5. The galvanometer servo mechanism moves to the center position of the black aluminum plate in the XYZ direction. A laser rangefinder is used to test and determine whether it is at the focal height. The laser rangefinder can be the rangefinder built into the galvanometer or an external rangefinder fixed on the galvanometer field lens or the mechanism that drives the galvanometer. The rangefinder output is sent to the main controller. The upper and lower limits of the rangefinder output can be set and controlled through the human-machine interface. 6. After the focal position is determined to be OK, the galvanometer outputs a corresponding signal to the main controller. The main controller communicates with the galvanometer software calibration module, calibrates the reference arm length, finds the optimal focal length, outputs relevant signals to the main program controller, and outputs an enable signal to the laser after processing to control the light output and complete the software calibration operation. 7. After calibration, each mechanism will return to the origin according to the predetermined trajectory, and the equipment PLC will automatically exit the calibration process.

[0023] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A rapid calibration method for a high-power laser galvanometer with OCT function, characterized in that, Includes the following steps: Step 1: Select the galvanometer calibration function on the device's human-machine interface, and the main controller will enter calibration mode; Step 2: Control the galvanometer drive mechanism to raise the galvanometer to a safe height and move it along a preset trajectory above the fixed calibration stage; Step 3: Use a CCD recognition device to photograph the calibration test piece to confirm whether the galvanometer is centered on the test piece; Step 4: Control the galvanometer servo mechanism to move in the XYZ directions, use a laser rangefinder to detect the height distance between the galvanometer and the test piece, and feed the measurement result back to the main controller; Step 5: The main controller combines the detection signal from the OCT module to determine the focal height, and performs compensation control based on the detection result to ensure that the focal height meets the preset conditions; Step 6: After the focal height is determined to be qualified, the main controller sends a signal to the galvanometer software calibration module to perform reference arm length calibration and optimal focal length optimization. Step 7: The main controller outputs an enable signal to control the laser to emit light, and the software automatically identifies the solder joints to complete the calibration. Step 8: After calibration is completed, each mechanism resets according to the predetermined trajectory, and the main controller exits the calibration mode.

2. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: The calibration platform is fixedly installed inside the equipment and is used to place black aluminum plates or perforated aluminum foil test pieces.

3. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: The main controller is a PLC or robot controller, used to detect the status of each mechanism of the equipment and control the operation of the galvanometer servo mechanism, CCD recognition device, laser rangefinder and OCT module.

4. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: The CCD recognition method can be any one of template matching, feature extraction, or coordinate system transformation.

5. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: The laser rangefinder is either a rangefinder integrated into the galvanometer or an external rangefinder mounted on the galvanometer field lens or the galvanometer drive mechanism.

6. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: The OCT module communicates with the main controller to output the focus height detection result, and the main controller performs automatic compensation control based on the detection result.

7. The rapid calibration method for a high-power laser galvanometer with OCT function according to claim 1, characterized in that: During the calibration process, the main controller communicates in real time with the galvanometer software calibration module and the OCT module to automatically complete the reference arm length calibration and focal length optimization.

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