Carbon dioxide laser segmented smooth splicing and trimming method for large-size glass explosion-proof membrane

Abstract

The invention belongs to the technical field of large-size glass processing, and particularly relates to a carbon dioxide laser segmented smooth splicing and trimming method for a large-size glass explosion-proof membrane. According to the technical scheme, the carbon dioxide laser segmented smooth splicing and trimming method for the large-size glass explosion-proof membrane comprises the following steps of S1, logic partitioning and global calibration; s2, carrying out super-amplitude lamination; s3, carrying out partition contour acquisition and fusion; s4, performing segmented path planning; s5, carrying out segmented smooth cutting; and S6, carrying out global quality inspection. According to the carbon dioxide laser segmented smooth splicing and trimming method for the large-size glass explosion-proof membrane, the stroke limitation of a CO2 laser galvanometer is broken through, segmented cutting and seamless splicing are achieved, and it is guaranteed that all-region membrane edge steps of large-size glass are uniform and free of splicing traces.

Description

Technical Field

[0001] This invention belongs to the field of large-size glass processing technology, and specifically relates to a method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation. Background Technology

[0002] Current technology for large-size glass products with a side length exceeding 600mm, such as automotive screens and ultra-large industrial control glass, is limited by the effective stroke of the CO2 laser galvanometer, making it impossible for a single galvanometer to achieve full-area one-time cutting; using an integral motion platform for cutting will result in a decrease in positioning accuracy. Existing segmented cutting technology does not have dedicated partitioning calibration and smooth transition logic designed for CO2 lasers. After segmented cutting, defects such as obvious splicing marks, abrupt step changes, and discontinuous edges are likely to occur. Moreover, large-size glass has larger tolerances, making the uneven step problem more prominent. Summary of the Invention

[0003] To address the aforementioned problems in existing technologies, the present invention aims to provide a method for smooth splicing and trimming of large-size glass explosion-proof films using carbon dioxide laser segmentation. This method overcomes the limitations of the CO2 laser galvanometer travel, achieves seamless splicing of segmented cutting, and ensures uniform edge steps and no splicing marks across the entire surface of large-size glass films.

[0004] The technical solution adopted in this invention is as follows: A method for smooth splicing and trimming large-size glass explosion-proof film using carbon dioxide laser segmentation includes the following steps: S1: Logical partitioning and global calibration: Based on the effective processing stroke of the CO2 laser galvanometer, the large-size glass cover is divided into several cutting sub-regions. The dual-view vision inspection module performs high-precision coordinate calibration on each cutting sub-region to establish a unified global splicing coordinate system. S2: Overwidth bonding: The large-size full-width explosion-proof film is bonded to the glass cover plate, and the explosion-proof film is controlled to form a uniform outward extension reserve throughout the glass area; S3: Partition contour acquisition and fusion: The visual inspection module cuts out sub-regions one by one to acquire the actual contour data of the glass, and performs coordinate fusion through the global splicing coordinate system to generate a complete large-size glass real global contour model, while completing global fitting offset compensation. S4: Segmented path planning: Based on the fused global contour model, a segmented CO2 laser cutting path is generated, and a smooth transition segment of 8-15mm is set at the junction of adjacent cutting sub-regions. S5: Segmented smooth cutting: The CO2 laser processing module cuts sub-regions one by one to perform cutting operations. Within the smooth transition section, the laser power and scanning speed are linearly and gradually adjusted. S6: Full-area quality inspection: After cutting, the flatness and step size of the film edge of the large-size glass are inspected by visual inspection equipment.

[0005] As a preferred embodiment of the present invention, in step S1, the effective processing stroke of the logical partition and global calibration CO2 laser galvanometer is 600mm×600mm, and the large-size glass cover plate of 1200mm×800mm is divided into 4 cutting sub-regions, the sub-region size is 600mm×600mm, and the adjacent sub-regions overlap by 10mm.

[0006] As a preferred embodiment of the present invention, in step S1, dual 5-megapixel visual cameras are used for global calibration, and a high-precision calibration plate with an accuracy of ±0.001mm is used to establish a unified global stitching coordinate system. The coordinate calibration accuracy of each sub-region is ±0.005mm, and the global coordinate fusion error is ≤±0.01mm.

[0007] As a preferred embodiment of the present invention, in step S2, a 0.125mm thick TPU explosion-proof film with a width of 1202mm×1002mm is selected for overwidth bonding and is bonded to the large-size glass. The bonding pressure is 0.4MPa, the bonding temperature is 40℃, the pressure holding time is 15s, and the single-sided overhang of the explosion-proof film is controlled to be 2.0mm. There are no bubbles, wrinkles, or local missing parts in the entire area.

[0008] As a preferred embodiment of the present invention, in step S3, the partition contour acquisition and fusion adopts a 3D line laser vision camera to cut sub-regions one by one to acquire the actual contour data of the glass with an acquisition accuracy of ±0.003mm, and extract the edge coordinates, corner curvature and size deviation of each sub-region; coordinate fusion is performed through the global splicing coordinate system to eliminate the calibration error between sub-regions, generate a complete real global contour model of the glass, and calculate the global bonding offset to complete the global path compensation.

[0009] As a preferred embodiment of the present invention, in the global fitting offset, the X / Y axis translation deviation is ≤ ±0.01mm and the rotation angle deviation is ≤ ±0.01°.

[0010] As a preferred embodiment of the present invention, in step S4, the segmented path planning is based on the global contour model to generate a segmented cutting path. The cutting path is based on the actual contour of the glass and offset inward by a safety margin of 0.08mm. At the junction of adjacent cutting sub-regions, a smooth transition segment of 10mm is set, and the path in the transition segment adopts circular interpolation.

[0011] As a preferred embodiment of the present invention, in step S5, the segmented smooth cutting uses a 50W radio frequency excited CO2 laser, paired with a three-axis gantry motion platform. The initial cutting parameters for each sub-region are set as follows: power 16W, cutting speed 300mm / s, defocusing amount +0.4mm, pulse frequency 20kHz, and coaxial blowing pressure 0.2Mpa. In the smooth transition section, the laser power smoothly transitions from 16W to the initial power of the adjacent sub-region according to a linear gradient curve, and the cutting speed smoothly transitions from 300mm / s to the initial speed of the adjacent sub-region according to a linear gradient curve, with no abrupt changes in the parameters. The negative pressure dust removal is activated simultaneously during the cutting process.

[0012] As a preferred embodiment of the present invention, when the laser power smoothly transitions from 16W to the initial power of the adjacent sub-region according to a linear gradient curve, the deviation is ≤0.5W; when the cutting speed smoothly transitions from 300mm / s to the initial speed of the adjacent sub-region according to a linear gradient curve, the deviation is ≤10mm / s; when the negative pressure dust removal is turned on simultaneously during the cutting process, the air volume is 600L / min.

[0013] As a preferred embodiment of the present invention, in step S6, the full-area quality inspection adopts a fully automatic visual inspection device with a detection range of 2000mm×1500mm to perform 100% inspection on the entire edge of the large-size glass film. The inspection items include step size, edge flatness, splicing marks, and heat-affected zone width; the inspection accuracy is ±0.003mm, the full-area step size is controlled within 0.08~0.13mm, the edge flatness is ≤±0.01mm, there are no visible splicing marks, and the heat-affected zone is ≤0.05mm.

[0014] The beneficial effects of this invention are as follows: 1. This invention breaks through the travel limitation of CO2 laser galvanometers and can be adapted to the processing of ultra-large glass cover plates of any size.

[0015] 2. This invention ensures consistent edge trimming accuracy across the entire area of ​​large-size glass by using zonal calibration and coordinate fusion, thus solving the problem of uneven steps in large-size products.

[0016] 3. The present invention features a smooth transition section with linearly varying parameters, enabling seamless splicing of segmented cuts without seams or abrupt changes in steps.

[0017] 4. This invention combines a dual closed-loop compensation mechanism, which can stably control the step deviation of ultra-large glass across the entire area to within 0.15mm. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the division of the large-size glass cutting sub-region in this invention; Figure 2 This is a schematic diagram of the global splicing coordinate system calibration of the present invention; Figure 3This is a schematic diagram of the segmented path and smooth transition segment of the present invention; Figure 4 This is a schematic diagram of the parameter gradient for the segmented smooth cutting of the present invention.

[0019] In the diagram: 1-Large glass cover plate; 2-Cut sub-area; 3-Smooth transition section; 4-Global splicing coordinate system; 5-Actual glass outline; 6-Cut path; 7-Power gradient curve; 8-Speed ​​gradient curve. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the invention can be combined with each other.

[0022] like Figures 1-4 As shown, this embodiment of a method for smooth splicing and trimming large-size glass explosion-proof film using carbon dioxide laser segmentation is based on an improvement of the dual closed-loop fine trimming process of Patent 1, and specifically includes the following steps: S1: Logical Partitioning and Global Calibration: Based on the effective processing stroke of the CO2 laser galvanometer, the large-size glass cover plate 1 is divided into several cutting sub-regions 2. A dual-view vision inspection module is used to perform high-precision coordinate calibration on each cutting sub-region 2, establishing a unified global splicing coordinate system 4. This step overcomes the limitations of the galvanometer's stroke, providing a unified benchmark for segmented cutting.

[0023] S2: Overwidth Lamination: The large-size, full-width explosion-proof film is laminated to the glass cover plate, ensuring that the explosion-proof film extends evenly across the entire glass surface. This step guarantees full coverage and allows for segmented trimming operations.

[0024] S3: Partition Contour Acquisition and Fusion: The visual inspection module sequentially cuts sub-regions 2 to acquire actual glass contour data 5, and performs coordinate fusion through the global stitching coordinate system 4 to generate a complete large-size glass real global contour model, while simultaneously completing global bonding offset compensation. This step eliminates the inherent tolerances and bonding offsets of the large-size glass, ensuring consistent global accuracy.

[0025] S4: Segmented Path Planning: Based on the fused global contour model, a segmented CO2 laser cutting path 6 is generated. At the junction of adjacent cutting sub-regions 2, a smooth transition segment 3 of 8-15mm is set. This step provides the path basis for seamless splicing and avoids the generation of seams.

[0026] S5: Segmented Smooth Cutting: The CO2 laser processing module performs cutting operations on sub-regions 2 one by one. Within the smooth transition section 3, the laser power and scanning speed are linearly and gradually adjusted to avoid cutting seams caused by abrupt parameter changes, achieving seamless splicing. This step eliminates splicing defects through parameter gradual change and ensures edge continuity.

[0027] S6: Full-area quality inspection: After cutting, visual inspection equipment is used to check the flatness and step size of the entire edge of the large-size glass film to ensure that the step deviation is uniform and controllable throughout the entire area. This step verifies the processing effect and ensures product consistency.

[0028] This invention breaks through the travel limitations of CO2 laser galvanometers, making it suitable for processing ultra-large glass cover plates of any size. Through partition calibration and coordinate fusion, it ensures consistent edge trimming accuracy across the entire area of ​​large-size glass, solving the problem of uneven steps in large-size products. The smooth transition section 3, combined with linear parameter gradients, achieves seamless splicing of segmented cutting, with no seams or abrupt step changes. Combined with a dual closed-loop compensation mechanism, the step deviation across the entire area of ​​ultra-large-size glass can be stably controlled within 0.15mm.

[0029] Example: This optimal implementation method is designed for large-size products such as 1200mm×800mm automotive screen glass and 1500mm×1000mm industrial control screen glass. It adopts the optimal partitioning strategy, calibration accuracy and cutting parameters to achieve seamless and high-precision segmented trimming.

[0030] 1. Logical partitioning and global calibration: The effective processing stroke of the CO2 laser galvanometer is 600mm × 600mm. The large-size glass cover plate 1 (1200mm × 800mm) is divided into 4 cutting sub-regions 2 (1#, 2#, 3#, 4#), with a sub-region size of 600mm × 600mm and an overlap of 10mm between adjacent sub-regions. Figure 1 As shown). Dual 5-megapixel visual cameras were used for global calibration. A high-precision calibration board (accuracy ±0.001mm) was used to establish a unified global stitching coordinate system. The coordinate calibration accuracy of each sub-region was ±0.005mm, and the global coordinate fusion error was ≤±0.01mm. Figure 2 (As shown).

[0031] 2. For overwidth lamination, a full-width 1202mm×1002mm TPU explosion-proof film (0.125mm thick) is used to laminate with large-size glass. The lamination pressure is 0.4MPa, the lamination temperature is 40℃, and the pressure holding time is 15s. The single-sided overhang of the explosion-proof film is controlled to be 2.0mm. There are no bubbles, wrinkles, or local missing areas throughout the entire area, and the trimming allowance of each sub-area is guaranteed to be uniform.

[0032] 3. The partition contour acquisition and fusion uses a 3D line laser vision camera to cut sub-regions one by one to acquire the actual contour data of the glass 5, with an acquisition accuracy of ±0.003mm. The edge coordinates, corner curvature, and dimensional deviation of each sub-region are extracted. Coordinate fusion is performed through the global stitching coordinate system 4 to eliminate the calibration error between sub-regions and generate a complete real global contour model of the glass. At the same time, the global fitting offset is calculated (X / Y axis translation deviation ≤ ±0.01mm, rotation angle deviation ≤ ±0.01°) to complete the global path compensation.

[0033] 4. Segmented path planning is based on the global contour model to generate segmented cutting paths 6. Cutting paths 6 are based on the actual glass contour 5, with an inward offset of 0.08mm safety margin; at the junction of adjacent cutting sub-regions 2, a smooth transition segment 3 of 10mm is set. Figure 3 As shown in the figure, the path within the transition section uses circular interpolation to ensure that the path is continuous without breaks and to avoid abrupt changes in the cutting direction.

[0034] 5. Segmented smooth cutting uses a 50W RF-excited CO2 laser, paired with a three-axis gantry motion platform. The initial cutting parameters for each sub-region are set as follows: power 16W, cutting speed 300mm / s, defocusing amount +0.4mm, pulse frequency 20kHz, and coaxial blowing pressure 0.2MPa. Within the smooth transition section 3, the laser power smoothly transitions from 16W to the initial power of the adjacent sub-region according to a linear gradient curve (deviation ≤0.5W), and the cutting speed smoothly transitions from 300mm / s to the initial speed of the adjacent sub-region according to a linear gradient curve (deviation ≤10mm / s). The parameters change gradually without abrupt changes. Figure 4 (As shown). The negative pressure dust removal system (airflow 600L / min) is activated simultaneously during the cutting process to prevent smoke and dust from affecting the cutting accuracy.

[0035] 6. Full-area quality inspection utilizes fully automated visual inspection equipment (inspection range 2000mm×1500mm) to perform 100% inspection of the entire edge of the large-size glass film. Inspection items include step dimensions, edge flatness, splicing marks, and the width of the heat-affected zone. Inspection accuracy is ±0.003mm, with the overall step dimensions controlled between 0.08-0.13mm, edge flatness ≤±0.01mm, no visible splicing marks, and a heat-affected zone ≤0.05mm.

[0036] 7. Optimal Implementation Results Under this optimal implementation method, large-size glass cover plates with a single-side dimension ≥600mm can be stably processed, breaking through the travel limit of CO2 laser galvanometer; the step deviation is uniform and controllable throughout the entire range, with no splicing marks or abrupt step changes; the processing yield is ≥99.5%, which fully meets the assembly and appearance requirements of large-size high-end products such as vehicle screens and industrial control screens, and is suitable for mass automated production.

[0037] Alternative Implementation Example 1 (Irregularly Shaped Large-Size Glass Solution): This embodiment is applicable to large-sized, irregularly shaped glass (such as curved automotive screens and irregular industrial control panels), optimizing the partitioning and path planning logic. Specific improvements include: dividing the glass into irregular sub-regions based on its contour (the shape of each sub-region adapts to the local contour of the glass), with the number of sub-regions adjusted as needed (3-6); setting the length of the smooth transition segment 3 to 8-12mm, and using Bezier curve interpolation for the transition segment path; and employing multi-camera stitching imaging for partition contour acquisition, adapted to irregular contour acquisition. This solution can process any large-sized, irregularly shaped glass, with invisible stitching marks, step dimensions controlled within 0.09-0.14mm, and a yield rate ≥99%.

[0038] Alternative Example 2 (High-Speed ​​Mass Production Large Size Solution): This embodiment is applicable to the mass production of large-size glass, optimizing cutting efficiency and cycle time. Specific improvements include: using a larger stroke galvanometer (800mm × 800mm) to reduce the number of sub-regions (e.g., dividing a 1500mm × 1000mm glass into 3 sub-regions); increasing the cutting speed to 350mm / s; shortening the transition time of the three parameters in the smooth transition section to 0.1s; and performing zone contour acquisition and cutting simultaneously (acquiring while cutting), further reducing the processing cycle time. This solution achieves a single-piece processing cycle time ≤90s, a 30% improvement over the original optimal embodiment, with the overall step size controlled within 0.09–0.15mm and a yield rate ≥99.2%, meeting mass production efficiency requirements.

[0039] This invention is not limited to the above-described optional embodiments. Anyone can derive other various forms of products under the guidance of this invention. However, regardless of any changes made in their shape or structure, any technical solution that falls within the scope of the claims of this invention shall be protected by this invention.

Claims

1. A method for smooth splicing and trimming large-size glass explosion-proof film using carbon dioxide laser segmentation, characterized in that: Includes the following steps: S1: Logical partitioning and global calibration: Based on the effective processing stroke of the CO2 laser galvanometer, the large-size glass cover plate (1) is divided into several cutting sub-regions (2). The dual-view vision inspection module performs high-precision coordinate calibration on each cutting sub-region (2) to establish a unified global splicing coordinate system (4). S2: Overwidth bonding: The large-size full-width explosion-proof film is bonded to the glass cover plate, and the explosion-proof film is controlled to form a uniform outward extension reserve throughout the glass area; S3: Partition contour acquisition and fusion: The visual inspection module cuts out sub-regions one by one (2) to acquire the actual contour (5) data of the glass, and performs coordinate fusion through the global splicing coordinate system (4) to generate a complete large-size glass real global contour model, while completing global fitting offset compensation. S4: Segmented path planning: Based on the fused global contour model, a segmented CO2 laser cutting path (6) is generated, and a smooth transition segment (3) of 8-15mm is set at the junction of adjacent cutting sub-regions (2). S5: Segmented smooth cutting: The CO2 laser processing module cuts sub-regions one by one (2) to perform cutting operations. In the smooth transition section (3), the laser power and scanning speed are linearly and gradually adjusted. S6: Full-area quality inspection: After cutting, the flatness and step size of the film edge of the large-size glass are inspected by visual inspection equipment.

2. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S1, the effective processing stroke of the logical partition and global calibration CO2 laser galvanometer is 600mm×600mm. The large-size glass cover plate (1) of 1200mm×800mm is divided into 4 cutting sub-regions (2), with the sub-region size being 600mm×600mm and adjacent sub-regions overlapping by 10mm.

3. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 2, characterized in that: In step S1, dual 5-megapixel visual cameras are used for global calibration. A high-precision calibration plate with an accuracy of ±0.001mm is used to establish a unified global splicing coordinate system (4). The coordinate calibration accuracy of each sub-region is ±0.005mm, and the global coordinate fusion error is ≤±0.01mm.

4. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S2, a 0.125mm thick TPU explosion-proof film with a full width of 1202mm×1002mm is selected for overwidth bonding and is bonded to the large-size glass. The bonding pressure is 0.4MPa, the bonding temperature is 40℃, the pressure holding time is 15s, and the single-sided overhang of the explosion-proof film is controlled to be 2.0mm. There are no bubbles, wrinkles, or local missing parts in the entire area.

5. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S3, the partition contour acquisition and fusion uses a 3D line laser vision camera to cut sub-regions one by one (2) to acquire the actual contour (5) data of the glass, with an acquisition accuracy of ±0.003mm. The edge coordinates, corner curvature, and size deviation of each sub-region are extracted. The coordinate fusion is performed through the global splicing coordinate system (4) to eliminate the calibration error between sub-regions and generate a complete real global contour model of the glass. At the same time, the global bonding offset is calculated to complete the global path compensation.

6. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 5, characterized in that: In the global fitting offset, the X / Y axis translation deviation is ≤ ±0.01mm, and the rotation angle deviation is ≤ ±0.01°.

7. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S4, the segmented path planning is based on the global contour model to generate a segmented cutting path (6). The cutting path (6) is based on the actual glass contour (5) and offset inward by a safety margin of 0.08mm. At the junction of adjacent cutting sub-regions (2), a smooth transition segment (3) of 10mm is set, and the path in the transition segment is interpolated by circular arc.

8. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S5, the segmented smooth cutting uses a 50W radio frequency excited CO2 laser, paired with a three-axis gantry motion platform. The initial cutting parameters for each sub-region are set as follows: power 16W, cutting speed 300mm / s, defocusing amount +0.4mm, pulse frequency 20kHz, and coaxial blowing pressure 0.2Mpa. In the smooth transition section (3), the laser power smoothly transitions from 16W to the initial power of the adjacent sub-region according to a linear gradient curve, and the cutting speed smoothly transitions from 300mm / s to the initial speed of the adjacent sub-region according to a linear gradient curve. The parameters change gradually without abrupt changes. The negative pressure dust removal is turned on simultaneously during the cutting process.

9. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 8, characterized in that: When the laser power smoothly transitions from 16W to the initial power of the adjacent sub-region according to a linear gradient curve, the deviation is ≤0.5W; when the cutting speed smoothly transitions from 300mm / s to the initial speed of the adjacent sub-region according to a linear gradient curve, the deviation is ≤10mm / s; when the negative pressure dust removal is turned on simultaneously during the cutting process, the air volume is 600L / min.

10. The method for smooth splicing and trimming of large-size glass explosion-proof film using carbon dioxide laser segmentation according to claim 1, characterized in that: In step S6, the full-area quality inspection uses a fully automatic visual inspection device with a detection range of 2000mm×1500mm to perform 100% inspection on the entire edge of the large-size glass film. The inspection items include step size, edge flatness, splicing marks, and width of heat-affected zone; the inspection accuracy is ±0.003mm, the full-area step size is controlled within 0.08~0.13mm, the edge flatness is ≤±0.01mm, there are no visible splicing marks, and the heat-affected zone is ≤0.05mm.

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