Alignment method, projection method and 3D printing method for joining light source modules

Abstract

The present invention discloses an orientation method, a projection method, a 3D printing method, an orientation device, a 3D printer, and a non-volatile computer-readable storage medium for joining light source modules, in which there are at least two light source modules, and the orientation method includes the steps of performing optical orientation processing on each light source module, in which a joining overlap area exists in the projection area of ​​the optically aligned light source module, and performing an orientation accuracy inspection on each optically aligned light source module based on the joining overlap area.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to a Chinese patent application bearing application number 202111113482.8 and entitled "Orientation method, projection method and 3D printing method for joining light source modules," filed with the State Intellectual Property Office of China on September 18, 2021, the entire contents of which are incorporated herein by reference. [Technical Field]

[0002] The present application relates to an orientation method, a projection method and a 3D printing method for joining light source modules. [Background technology]

[0003] Common digital light processing 3D printing technologies are DLP (Digital Light Processing) technology and LCD (Liquid Crystal Display) technology. DLP technology, developed by Texas Instruments, modulates the illumination surface light source output by a DMD (Digital Micromirror Device), projects it onto a receiving screen, and outputs the pattern that needs to be exposed. Here, the DMD device is the basis of DLP, and one DMD can be simply described as a semiconductor optical switch. LCD technology is similar, modulating the output light with a liquid crystal layer inside an LCD screen to display the image that needs to be exposed.

[0004] Texas Instruments DMD devices have an upper limit on the optical power of the modulated light source, and the projection accuracy gradually decreases as the projection width increases. 3D printing devices using DLP technology have limitations on the maximum width and maximum printing accuracy.

[0005] However, the inventors have attempted to use conventional technology by joining the projected width surfaces of DLP optical devices together, but the optical system of the optical device contains optical aberrations, which causes the projected width surfaces of multiple DLP optical devices to be joined unnaturally, resulting in the loss of information about the edge of the width surface. When used in the 3D printing field, there are joining defects such as seams and protrusions, which affect the use of printing components. Summary of the Invention [Problem to be solved by the invention]

[0006] The embodiments of the present invention provide an orientation method, a projection method, a 3D printing method and an orientation system for joining light source modules, with the aim of solving the problem of joining defects caused by joining multi-light machines and improving the projection effect and 3D printing effect. [Means for solving the problem]

[0007] In a first aspect, an embodiment of the present invention provides an orientation method for joining light source modules, which includes at least two light source modules, and includes the steps of performing optical orientation processing on each light source module, where a joining overlap area exists in the projection area of ​​each light source module, and performing an orientation accuracy inspection of the joining overlap for each light source module that has been optically aligned based on the joining overlap area.

[0008] In a second aspect, an embodiment of the present invention provides a projection method, in which there are at least two light source modules, and the projection method includes the steps of: performing segmentation processing on a slice image to be projected based on the projection area of ​​each light source module to obtain a plurality of segmented images; and performing image information gradual variation processing on the overlapping area of ​​the segmented images, and transmitting the processed segmented images to corresponding light source modules, respectively, where each light source module is obtained by orientation using any of the above orientation methods.

[0009] In a third aspect, an embodiment of the present invention provides a 3D printing method, comprising the steps of: performing a slicing process on a three-dimensional data model to obtain several slice images; and sequentially performing any of the above projection methods on each slice image according to a projection order of the predetermined slice images.

[0010] In a fourth aspect, an embodiment of the present invention provides an orientation device for joining light source modules, the light source modules being at least two, the orientation device being for performing optical orientation processing on each light source module, the orientation device having a joining overlap area in the projection area of ​​each light source module, and a verification device being for performing orientation accuracy inspection of the joining overlap for each light source module that has been optically positioned in the joining overlap area.

[0011] In a fifth aspect, embodiments of the present invention provide a three-dimensional printer, comprising a memory and one or more processors, the memory having computer-readable instructions stored therein, the processors performing the steps of any of the methods described above when executing the computer-readable instructions. In a sixth aspect, an embodiment of the present invention provides a non-volatile computer-readable storage medium having computer-readable instructions stored thereon, the computer-readable instructions being adapted to implement the steps of any of the above methods when executed by a processor. [Effects of the Invention]

[0012]

[0013] Embodiments of the present invention provide an orientation method, projection method, 3D printing method, orientation device, 3D printer, and computer-readable storage medium for joining light source modules, wherein there are at least two light source modules, and the orientation method includes the steps of performing optical orientation processing on each light source module, whereby a joining overlap area exists in the projection area of ​​each light source module, and testing the orientation accuracy of the joining overlap for each optically aligned light source module based on the joining overlap area. By performing orientation processing during the joining process of the light source modules, the occurrence of joining lines and pixel information disturbance during joining can be avoided, thereby solving the problem of joining defects caused by joining light source modules and improving the projection and 3D printing effects. [Brief explanation of the drawings]

[0013] In order to more clearly describe the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings that need to be used in the description of the embodiments. Obviously, the drawings in the following description are some embodiments of the present invention, and those skilled in the art can further derive other drawings based on these drawings without any creative efforts. [Figure 1] 1 is a first flow chart diagram of an orientation method for joining light source modules according to one or more embodiments. [Figure 2] 10 is a second flowchart schematic diagram of an orientation method for joining light source modules according to one or more embodiments. [Figure 3] 1 is a simplified flowchart of steps for physically joining light source modules in one or more embodiments. [Figure 4] 1 is an exemplary diagram of an apparatus for locating a light source module in accordance with one or more embodiments. FIG. [Figure 5] FIG. 10 is an example schematic diagram of a physical joint positioning block diagram in an orientation method for light source module joints in one or more embodiments. [Figure 6]FIG. 10 is a simplified flowchart of the steps for performing a splice overlap orientation accuracy inspection on each optically aligned light source module in one or more embodiments. [Figure 7] 1 is an exemplary diagram of an orientation tool in an orientation method for joining light source modules in accordance with one or more embodiments. FIG. [Figure 8] 1 is a schematic flow chart of steps for performing respective optical orientation processes for each light source module in one or more embodiments. [Figure 9] 10A-10C are standard projection views of orientation methods for connecting light source modules in one or more embodiments. [Figure 10] FIG. 10 is a schematic flow chart of steps for obtaining pitches based on the same coordinate system of projected and oriented identification points in one or more embodiments. [Figure 11] 1 is a schematic flow chart of a projection method according to one or more embodiments. [Figure 12] FIG. 1 is a simplified flowchart of steps for performing a slicing process on a three-dimensional data model in accordance with one or more embodiments. [Figure 13] FIG. 1 illustrates the effect of physical bonding in one or more embodiments. [Figure 14] 1 is a schematic block diagram of an orientation device for connecting light source modules according to one or more embodiments. [Figure 15] FIG. 1 is a structural schematic diagram of a printing surface and molding platform according to one or more embodiments. [Figure 16] FIG. 1 is a structural schematic diagram of a printing surface and forming pallet according to one or more embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, the technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some of the embodiments of the present invention, and not all of the embodiments, and all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without any creative efforts are all within the protection scope of the present invention.

[0015] It should be understood that when used in this specification and the appended claims, the terms "comprise" and "contain" indicate the presence of stated features, wholes, steps, operations, elements and / or assemblies, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, assemblies and / or groups thereof.

[0016] It is also to be understood that the terminology used in the specification of the present invention is for the purpose of describing particular embodiments only, and is not intended to be limiting of the present invention. As used in the specification of the present invention and the appended claims, the singular forms "a," "one," and "the" are intended to include the plural forms unless the context clearly dictates otherwise.

[0017] It should further be understood that the term "and / or" as used in the present specification and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

[0018] Regarding the definition of the printing surface, the optical system irradiates the projected image onto the printing surface, then hardens the photocurable liquid at the interface, resulting in a cured sheet material that matches the contours of the projected image. For example, in top-projection, surface-exposure, photocurable 3D printing, the printing surface is the liquid surface of the photocurable liquid, while in bottom-projection, surface-exposure, photocurable 3D printing, the printing surface is located at the bottom of the tray. It should be noted that the printing surface referred to in this specification only has one position and orientation relative to the optical system. When determining the printing surface, the positions of some components of the actual printer (e.g., tray 1, molding platform / molding pallet 2, light source 3, resin chute 4, printing surface 40, as shown in Figures 15 and 16) can be referenced. Here, Figure 15 illustrates a bottom-projection 3D printer, and Figure 16 illustrates a top-projection 3D printer. While the position of the printing surface can be quickly identified and determined in the printer, if any of the aforementioned components are missing, the position data information of the printing surface can also be confirmed based on the position data information of the aforementioned components.

[0019] Referring to FIG. 1, it shows an orientation method for joining light source modules provided in an embodiment of the present application, where the light source modules are at least two, and as shown in FIG. 1, the orientation method includes the following steps:

[0020] In S110, optical orientation processing is performed on each light source module, and a joint overlap area exists in the projection area of ​​the optically-oriented light source module; Here, the light source module may be any display assembly known in the art that can display exposed image information, specifically a laser display device that can display the exposed image information, or a projection device that can project the exposed image information, such as a DLP projection module, an LCD projection module, an OLED projection module, an LCOS (Liquid Crystal On Silicon) projection module, a Micro-Led (micro light emitting diode) module, a Mini-Led (mini light emitting diode) module, an LCD module, an OLED module, and an SXRD (Silicon X-Tal Reflective Display) projection module, or any combination thereof, or may be a Micro-OLED module or a Mini-OLED module. Optical alignment is a processing method for correcting an image displayed by the light source module.

[0021] Specifically, the number of light source modules may be two or more, and the joining method may be two-dimensional expansion joining based on any of the light source modules, or one-dimensional expansion joining based on any of the light source modules. For example, when the number of light source modules is four, two-dimensional expansion joining means that one light source module is joined in each of the horizontal, vertical, and diagonal directions of any of the light source modules. One-dimensional expansion joining means that three light source modules are joined sequentially in the horizontal or vertical direction of any of the light source modules. Note that the above horizontal, vertical, and diagonal directions are used for illustrative purposes only and do not constitute a limiting description of one-dimensional expansion joining and two-dimensional expansion joining.

[0022] The projection area may be a projection area projected onto a printing surface or a projection area projected onto an orientation tool. In other words, there may be overlapping areas in the projection area, and in terms of actual display, the projection areas on the printing surface of multiple light source modules may overlap each other, or the projection areas on the orientation tools of multiple light source modules may overlap each other. The projection areas of the light source modules may have overlapping areas both before and after the optical orientation process.

[0023] In step S120, the splice orientation accuracy is inspected for each optically aligned light source module based on the splice area.

[0024] Here, the orientation accuracy test verifies the deviation that occurs during bonding, i.e., orientation test. Specifically, the orientation accuracy can be confirmed based on the overlapping projected feature points in the bonding overlapping area of ​​each light source module or the gap between the projected feature points and the reference point. In one specific example, the orientation accuracy can be determined based on the deviation between the center coordinates of the overlapping projected feature points and the photolithography points (also called orientation points or reference point) in the orientation tool. In another specific example, the orientation accuracy can be determined based on the shape of each overlapping projected feature point. In another specific example, the orientation accuracy can be determined based on the overlapping ratio of the projected feature points. In another specific example, the overlapping accuracy of the overlapping reference point of the bonding area structure can be checked and the orientation accuracy can be evaluated based on the deviation (or coordinate difference value) between the projected feature points and the reference position. It should be noted that the above-mentioned several orientation accuracy test methods are merely exemplary methods provided in the embodiments of this application. In actual applications, any method that can realize the orientation accuracy test for each optically aligned light source module is within the scope of protection of this application. Furthermore, if the orientation accuracy inspection fails, the process proceeds to step S110, where orientation is performed again.

[0025] The above-described orientation method performs optical orientation processing during the light source module joining process, thereby avoiding the occurrence of joining lines and pixel information distortion during joining, thereby solving the joining defects caused by multiple light source joining and improving the projection and 3D printing effects. The solution of this embodiment reduces the deviation of the aligned joining to within one pixel. Furthermore, this embodiment is not only applicable to the 3D printing industry, but can also be used in industries related to other DLP technologies. For example, the orientation method provided in this embodiment can be used to join patterns in UV-band DLP light sources or other different band DLP technologies. The solution of this embodiment / the orientation method is as follows: No bezel 、 Display technology that enables superimposed displays Also applicable to is. For example, in LCD projection technology, Lcos projection technology, and SXRD projection technology, the displayed screen can also be joined using the orientation method provided in this embodiment. It should also be noted that in specific application scenarios, the light source module may be specifically an optical device. Through the above orientation method, the deviation of the orientation and joining is within one pixel, and the accuracy of the overall projected image reaches the sub-pixel level.

[0026] Please refer to FIG. 2, which shows a flowchart of another location method, as shown in FIG. 2, the location method includes:

[0027] Before the splice overlap orientation accuracy inspection is performed on each optically aligned light source module, the following steps are further included:

[0028] In step S210, the light source modules are physically connected together so that the projection area of ​​each light source module meets the requirement of a predetermined projection width.

[0029] Here, physical connection refers to changing the projection area of ​​the light source module, for example, by moving the light source module or moving a reflecting mirror. Specifically, physical connection can be achieved for each light source module by any means known in the art, such as by installing an orientation adjustment mechanism for orientation. Each orientation adjustment mechanism includes a light source adjustment structure that can translate along the X, Y, and Z axes and rotate horizontally and angularly. The requirement for a given projection width may be the positional or dimensional requirements that the projection area must meet. For example, the light source module can be moved to overlap the projection area so that it completely covers the area of ​​the printing surface. Alternatively, the light source module can be moved to overlap the projection area so that it is the same as the orientation area of ​​the orientation tool in the optical orientation process.

[0030] In S220, optical orientation processing is performed for each light source module, and a joint overlap area exists in the projection area of ​​the optically-oriented light source module; In S230, based on the spliced ​​area, the spliced ​​orientation accuracy of each optically aligned light source module is inspected.

[0031] In this embodiment, the light source modules to be optically aligned are physically joined, and then the alignment plate is used to perform distortion alignment for the physically joined light source modules, i.e., alignment is performed for each light source module, and then alignment inspection is performed for the entire light source module. The deviation after physical joining is within 10 pixels. By performing physical joining before alignment, the projection area of ​​each light source module can meet the required projection width, and the number of pixels lost during the alignment process for each light source module can be reduced.

[0032] It should be noted that the execution order of steps S210 and S220 can be interchanged in other embodiments. Specifically, the physical connection in step S210 can adjust the position and / or projection size of the light source module by human visual observation, and the accuracy is not as high as that of the optical orientation in step S220. Therefore, according to the normal operation, first coarse adjustment is performed and then fine adjustment is performed. In addition, the advantage of using a full-width plane orientation plate in the optical orientation step is that it not only corrects optical distortion, but also fine-tunes the position of the projection width plane (the position of the projection area), and each optical unit completes optical orientation based on the same orientation coordinate system.

[0033] However, if optical orientation is first performed on the light source modules (mainly to correct the optical distortion of each light source) and then physically joined, the accuracy of the physical joining is limited, so the next step must further fine-tune the position of the projection plane (the position of the projection area) corresponding to each light source module, and convert the pixel point coordinate system or the projected feature point coordinate system to the same coordinate system. In other words, after physical joining, an additional optical orientation must be performed, and one of the goals achieved by this optical orientation is to translate the pixel point coordinate system or the projected feature point coordinate system. Overall, placing step S210 before step S220 is more convenient than placing step S220 before step S210.

[0034] Please refer to FIG. 3, which shows a flowchart of physically joining each light source module, the steps of which include:

[0035] In step S310, the horizontal position of each light source module is adjusted so that the pitch between the first feature image boundary of the light source module and the orientation tool bezel satisfies a first predetermined distance, and the pitch between the second feature image projected by each light source module and the auxiliary image satisfies a second predetermined distance, where the orientation tool is provided on the printing surface and the auxiliary image is provided on the orientation tool. Here, the orientation tool is used for optical orientation and may be, for example, a positioning plate.

[0036] Specifically, a predetermined orientation tool (positioning frame) is placed in the printing area, and projection adjustment is performed on the light source module based on the positioning frame, so that the width surface of the light source module to be projected and joined can be observed through the positioning frame, and an auxiliary adjustment pattern (i.e., the above-mentioned auxiliary image) is present in the positioning frame. The light source module is installed to project a first feature image that matches the contour of the positioning frame, and the first feature image is a positioning image, specifically, it may be an all-white image. The horizontal position of the light source module is adjusted using a light source adjustment mechanism, for example, by adjusting the horizontal displacement and rotation angle of the light source module, so that the pitch between the boundary of the first feature image of the light source module and the positioning frame satisfies a first predetermined distance, where the first predetermined distance may be any number obtained according to actual measurement needs, for example, 0, that is, the boundary of the first feature image of the light source module overlaps with the positioning frame. The positioning image projected by each light source module is replaced with a feature image corresponding to the auxiliary adjustment pattern in the positioning frame, and the horizontal displacement and rotation of each light source module are adjusted so that the pitch between the boundary of the feature image (or the boundary of the projection area) of each light source module and the positioning frame (or the bezel of the orientation tool) satisfies a second predetermined distance, where the second predetermined distance may be any number obtained according to actual measurement needs, for example, 0, that is, the boundary of the feature image (or the boundary of the projection area) of each light source module overlaps with the positioning frame (or the bezel of the orientation tool).

[0037] In this embodiment, as shown in FIG. 4, the light source adjusting structure 10 is used to adjust the position of the light source module 20, and the position parameters of the light source module 20 are: This includes one or more of the horizontal position of the light source module 20, the vertical height of the light source module 20, the rotation angle of the light source module 20 around the X axis, the rotation angle of the light source module 20 around the Y axis, and the rotation angle of the light source module 20 around the Z axis.

[0038] Specifically, the light source modules 20 and the printing surface to be joined are adjusted to a parallel position, and the distance between all light source modules and the overall distance between the printing surface is further adjusted to achieve the required printing accuracy. The light source adjustment mechanism can be realized by mechanical structural design. In actual operation, the light source adjustment mechanism can be operated manually, or it can be installed to be driven by an electrical element (e.g., a motor). Adjusting the input signal of the electrical element controls the light source adjustment mechanism and further adjusts the position of the light source modules. Adjusting the orientation of the light source modules 20 can change the position of the image projected onto the printing surface 30 of the light source modules 20. Furthermore, an orientation tool 40 is installed on the printing surface, and an imaging module 50 is installed to capture an image of the printing surface 40. The image information corresponding to the image can include position information of the orientation identification points on the orientation tool 40 and position information of the projected feature points of the light source modules 20.

[0039] 5, a pre-installed orientation tool (which may be an orientation frame) is placed in the printing area, and the width of the orientation tool is divided into orientation frames for multiple light source modules, such as orientation frame 410 for light source module A, orientation frame 420 for light source module B, orientation frame 430 for light source module C, and orientation frame 440 for light source module D. The width of each light source module to be projected and joined can be observed through the orientation tool 40, and the orientation tool has an auxiliary adjustment pattern 401. Next, an orientation image that matches the outline of the orientation tool, specifically an all-white image, is projected onto each light source module 20, and the horizontal displacement and rotation of each light source module are correspondingly adjusted to visually confirm that the boundary of the all-white image of each light source module 20 overlaps with the bezel of the orientation tool. The projected images are then swapped, and a feature image corresponding to the auxiliary adjustment pattern 401 in the orientation tool is projected onto each light source module 20. The position of each light source module 20 is fine-tuned to visually confirm that the feature image overlaps with the auxiliary adjustment pattern, thereby completing the physical joining adjustment.

[0040] In specific operation, the positioning frames corresponding to each light source module can be integrated into a large full-width positioning frame whose covering area is the same as the width area after joining, so that when adjusting the position of each light source module, they are all the same of The adjustment is performed based on a coordinate system. Of course, the positioning frame corresponding to each light source module may be independent, and when performing a physical connection adjustment operation on a light source module, a positioning frame corresponding to the light source module is provided. The auxiliary adjustment pattern is mainly used to fine-tune the position of the light source module. The auxiliary adjustment pattern can be arbitrarily designed, for example, dots, a combination of regular or irregular patterns, lines, letters, polygons, irregular patterns, etc. The present application is not limited and is for illustrative purposes only. See FIG. 5 for an example of the auxiliary adjustment pattern.

[0041] The positioning frame can be formed from a light-transmitting, partially light-transmitting or non-light-transmitting plate or sheet material, as long as the projection of the light source module can be observed simultaneously with the positioning frame.

[0042] In a specific embodiment, the misalignment of the physically joined optical devices is within about 10 pixels (where a pixel is temporarily considered to be a unit of dimension).

[0043] In one embodiment herein, before adjusting the horizontal position of each light source module, further including:

[0044] In S300, the horizontality of each light source module relative to the printing surface and the vertical distance between each light source module and the printing surface are adjusted so that the light projection width of the light source module reaches a predetermined dimension.

[0045] Specifically, the predetermined dimension may correspond to the light projection width of one of the light source modules, or may correspond to a light projection width formed commonly by all the light source modules. In one specific example, each light source module to be joined is adjusted so that its horizontal plane and the printing surface meet a predetermined parallelism requirement, and then the overall distance between all the light source modules and the printing surface is adjusted so that the overall projection of all the light source modules is a width with the required printing accuracy. Note that printing accuracy refers to the pixel size of the light projection width, and at the same resolution, the pixel size determines the width size.

[0046] In one embodiment, the alignment method for connecting a light source module further includes:

[0047] The light projection widths of the optically aligned light source modules are adjusted so that the deflection angles and offset amounts of each light projection width based on the reference width meet a first predetermined requirement. In one specific example, the first predetermined requirement includes that the difference between the deflection angles of each light projection width based on the reference width be within a first predetermined range, and that the difference between the offset amounts of each light projection width based on the reference width be within a second predetermined range.

[0048] Here, the reference width plane can be specified according to the actual situation, and for example, a width plane formed by identification points marked on the orientation tool can be used as the reference width plane.

[0049] Specifically, the position of the light projection width plane can be adjusted by any means. After optical orientation processing is performed on each light source module, the projected feature points and orientation identification points of each light source module have a specific relative positional relationship (i.e., a specific deflection angle and offset amount). However, the relative positional relationship corresponding to each light source module may be different. Therefore, the deflection angle and offset amount corresponding to each light source module must be adjusted so that the difference between the deflection angles of each light projection width plane based on the reference width plane is within a first predetermined range, and the difference between the offset amounts of each light projection width plane based on the reference width plane is within a second predetermined range. Furthermore, both the first predetermined range and the second predetermined range can include zero, that is, the deflection angle and offset amount based on the reference width plane of each light projection width plane are the same.

[0050] Please refer to FIG. 6, which shows a schematic diagram of inspecting the alignment accuracy of the splice overlap for each optically aligned light source module, and the steps include:

[0051] In S610, a first current position of the projected feature point and a first standard position corresponding to the projected feature point are obtained, where the projected feature point is formed by projecting each light source module that has been optically aligned onto the printing surface; Here, the first standard position corresponding to the projected feature point can be confirmed by an orientation tool, for example, a photolithography point on the orientation tool.

[0052] Specifically, the first standard position and the first current position can be acquired by any means in the art, for example, by image identification. In one specific example, the step of acquiring the current positions of the projected feature points and the standard positions corresponding to the projected feature points includes the steps of acquiring image information of the printing surface, in which an orientation tool is provided on the printing surface and an orientation identification point for characterizing the standard position is provided on the orientation tool, and determining the first standard position and the first current position based on the image information.

[0053] In step S620, a deflection angle and an offset amount corresponding to each optically located light source module are determined based on the first current position and the first reference position; Specifically, the deflection angle and offset amount corresponding to each light source module subjected to optical orientation processing are the deflection angle and offset amount relative to the identification point marked on the orientation tool of the projected feature point at which each light source module is positioned.

[0054] In S630, if each deflection angle and each offset amount meets a second predetermined condition, it is determined that the location is successful.

[0055] Here, the second predetermined condition includes that the deviation between each deflection angle is within a third predetermined range and that the deviation between each offset amount is within a fourth predetermined range. The third and fourth predetermined ranges can include zero, i.e., the deflection angles corresponding to each light source module are the same and the corresponding offset amounts are also the same, thereby meeting the requirements for combining different light source modules. Furthermore, the first predetermined condition also includes that the offset amount corresponding to any light source module is within a corresponding predetermined interval, i.e., for each light source module, the offset amount must be within a predetermined interval, thereby meeting the requirements for individual orientation of each light source module.

[0056] Specifically, all optical modules project their feature maps onto the alignment plate, and then perform an alignment test on each single optical module in each region. The projected feature points in the spliced ​​and overlapping regions are randomly overlapped to form a single overlapping projected feature point. The coordinate positions of the overlapping projected feature points relative to the discriminant points are affected by the projected feature points of each single optical module, thereby determining the alignment error after the entire splicing process. Based on the divided full-width surface alignment discriminant point maps corresponding to the projected regions of each single optical module, each divided region is aligned with the region corresponding to the alignment of the previous single optical module. The alignment of each single optical module is repeated, and the difference between the coordinates of the aligned discriminant points in the spliced ​​and overlapping regions of each single optical module and the coordinates of the photolithography points can be obtained, thereby testing the overlap accuracy of the overlapping alignment discriminant points created in the spliced ​​regions.

[0057] In one embodiment, the step of inspecting the alignment accuracy of the splice overlap for each optically aligned light source module includes: obtaining a second current position of the overlapping projection feature point and a second standard position corresponding to the overlapping projection feature point, the overlapping projection feature point being obtained by projecting each of the optically aligned light source modules onto the joint overlapping region; Specifically, position acquisition can be performed using an image identification method. In one specific example, the step of acquiring the current positions of the projected feature points and the standard positions corresponding to the projected feature points includes the steps of acquiring image information of the printing surface, in which an orientation tool is provided on the printing surface and an orientation identification point for characterizing the second standard position is provided on the orientation tool, and determining the second current position and the second standard position based on the image information. If the deviation value between the second current position and the second standard position satisfies a second predetermined condition, it is determined that the orientation is successful. Furthermore, if the deviation value between the second current position and the second standard position does not satisfy the second predetermined condition, optical orientation processing is performed again for each light source module.

[0058] Specifically, a locating plate is placed on the printed surface, the light source module to be inspected is installed, and the light source module adjacent to the light source module to be inspected projects part or all of its standard projection onto the locating plate, so that the projected landmark points in the junction area of ​​the light source module to be inspected overlap to form at least one overlapping projection feature point, and a photographed image of the printed surface is obtained, the photographed image including the overlapping projection feature points and orientation discrimination points in the junction area of ​​the light source module to be inspected, and the difference between the coordinates of the overlapping projection feature point in the image coordinate system and the coordinates of the orientation discrimination point on the locating plate is obtained, and if the difference exceeds a predetermined error threshold, the light source module to be inspected needs to be re-oriented.

[0059] In this embodiment, after the orientation of each light source module is completed, the orientation accuracy test is performed for each light source module. The orientation plate is placed on the printing surface again, and the light source module to be inspected and the light source modules adjacent to the light source module to be inspected project some or all of the standard projection images onto the orientation plate, and the orientation test is performed for the light source module to be inspected.

[0060] First, the contact edges of adjacent orientation regions are placed in an orientation joint region. When adjacent light source modules both project standard projections, the projection feature points in the orientation joint region will overlap randomly, creating overlapping projection feature points. The coordinate positions of these overlapping projection feature points relative to the orientation discrimination points will be affected by the projection feature points oriented by each light source module, and thus the orientation error after the entire joint will be determined.

[0061] If joining is successful, the overlapping projected feature points in the orientation joining area are similar to the projected identification points without overlapping, i.e., the pattern of the projected identification points matches the pattern of the overlapping projected feature points, and the difference between the coordinates of the overlapping projected feature points and the coordinates of the orientation point is very small or smaller than a predetermined error threshold. If joining is unsuccessful, the pattern of the overlapping projected feature points in the orientation joining area does not match the pattern of the projected identification points without overlapping, and in summary, if the normal projected identification point pattern is square, the overlapping projected feature point pattern will be rectangular, polygonal, or irregular, and if the normal projected identification point pattern is circular, the overlapping projected feature point pattern will be elliptical or clearly non-circular, and in short, the coordinates of the center of the overlapping projected feature point pattern (specifically, selected from the center of gravity or center of mass) will be offset from the coordinates of the original projected identification point, and therefore the difference between the coordinates of the overlapping projected feature points and the coordinates of the orientation point will be very large or exceed a predetermined error threshold.

[0062] In the orientation inspection, the overlap projection feature points within the orientation joint area are mainly identified, so that the light source module to be inspected and the light source modules adjacent to the light source module to be inspected only need to project some standard projection images onto the orientation plate to ensure that the overlap projection feature points are formed within the joint area. Of course, for ease of operation, the light source module to be inspected and the light source modules adjacent to the light source module to be inspected may project all standard projection images, or even all light source modules may project all standard projection images together.

[0063] After the light source module is assembled, the standard projection is projected onto the entire light source module, and then the orientation test is carried out on the orientation results of each light source module. Overlapping projection feature points The overlapping accuracy of the overlapping orientation feature points can be confirmed. Specifically, the projected identification points correspond one-to-one to the photolithography points (i.e., the orientation identification points) on the orientation plate, and similarly, each overlapping orientation feature point also has a corresponding orientation identification point. The photographed image (specifically, the orientation plate image) of the divided printing surface corresponds to the orientation area of ​​each light source module, and each divided area coincides with the orientation area corresponding to each light source module. In this way, the coordinate difference between the overlapping orientation feature points and the orientation identification points in the orientation joint area of ​​each light source module can be obtained, thereby inspecting the overlapping accuracy of the overlapping orientation identification points created in the joint area. Here, the predetermined error threshold may be 0.5 pixels, 1 pixel, or any value between 0 and 1 pixel.

[0064] If the difference exceeds a predetermined error threshold, the light source module under test needs to be re-oriented; if the difference is smaller than the predetermined error threshold, it is proved that the orientation result satisfies the overlap accuracy.

[0065] By the above operation, the deviation after orientation and joining is within one pixel, and the accuracy of the whole projection image reaches the sub-pixel level.

[0066] In one embodiment, the step of performing optical orientation processing for each light source module includes a step of employing an orientation tool located in the same coordinate system to perform optical orientation processing for each light source module, or employing the same orientation tool to perform optical orientation processing for each light source module, wherein the coverage area of ​​the orientation tool is equal to or greater than the projection width surface obtained by joining the light source modules. Here, the orientation tool may be a orientation plate.

[0067] Specifically, all light source modules are orientated using the same orientation tool. As shown in Figures 7(a) and 7(b), orientation tool 10 is provided with orientation discrimination points 100, and the coverage area of ​​orientation tool 10 is equal to or greater than the width of the joined surface. In Figure 7(a), four light source modules are joined and the overlapping area includes the joining method of one orientation discrimination point, while in Figure 7(b), n light source modules are joined and the offset area includes the joining method of n orientation discrimination points. Note that each of the orientation areas of the light source modules in Figure 7(b) has an overlapping area. Figures 7(a) and 7(b) show orientation area 200 of light source module A, orientation area 300 of light source module B, orientation area 400 of light source module C, and orientation area 500 of light source module D, with an overlapping area 600 between the orientation areas of each light source module. Therefore, in the orientation process of each light source module, the orientation discrimination point matrices are all in the same coordinate system, so that in the subsequent orientation inspection step, it is not necessary to convert the pixel point coordinate system or the projected feature point matrix coordinate system corresponding to each light source module into the same coordinate system, making the orientation method simpler and faster.In addition, multiple orientation tools located in the same coordinate system can be used to perform the optical orientation process, and the coordinates of the mark discrimination points (photolithography points) of each orientation tool can be determined.

[0068] On the other hand, in other embodiments, multiple small target plates with areas smaller than that of the target plate of this embodiment may be used, and the coverage area of ​​the small target plates is consistent with the projected width of a single light source module. When targeting different light source modules, the position of the small target plate needs to be adjusted according to the projected position of the currently targeted light source module. In the subsequent targeting and inspection step, the pixel point coordinate system or the coordinate system of the projected feature point corresponding to each light source needs to be converted into the same coordinate system.

[0069] Please refer to FIG. 8, which shows a schematic diagram of performing optical orientation processing for each light source module respectively, and the steps include:

[0070] In S810, pitches of the projected identification points and the orientation identification points based on the same coordinate system are obtained, where the projected identification points are obtained by projecting a predetermined image onto a corresponding projection area using a light source module, an orientation tool is provided in the corresponding projection area, and the orientation identification points are provided on the orientation tool; Here, the positions of the orientation identification points and the projected identification points may be misaligned. An ideal projection map is a dot matrix map made up of projected points, and a corresponding dot matrix map is provided on the orientation board. In order to better distinguish between the orientation points and the projected points, the positions of the orientation board and the actual projection map are misaligned.

[0071] Specifically, the pitch based on the same coordinate system can be calculated after rotating one or two of the projected identification point and the orientation identification point and translating them to the same coordinate system.

[0072] In S820, each light source module is oriented based on pitch.

[0073] Specifically, the step of orienting each light source module based on the pitch, i.e., performing inverse distortion processing on the image to be projected, includes converting the pitch into an offset amount in a pixel coordinate system and orienting each light source module based on the offset amount. The step of converting the pitch into an offset amount in the pixel coordinate system includes constructing a corresponding pitch value matrix based on the pitch, associating each parameter in the pitch value matrix with the pixel coordinate system, and performing a fitting operation on the pitch value matrix to obtain a target matrix. The step of obtaining the offset amount includes obtaining the offset amount based on the target matrix, element coordinate position information in the pixel coordinate system, and physical dimensions corresponding to unit pixel points. In the step of obtaining the offset amount, the offset amount is obtained using the following formula:

[0074] C1=C0+T'0P' Here, C1 is the offset amount, C0 is the element coordinate position information, T'0 is the target matrix, and P' is the physical dimension corresponding to the unit pixel point.

[0075] 9 , in this embodiment, a given image is divided into several mesh regions, and the vertices of each mesh region are represented as projected identification points. The mesh is a polygonal mesh, specifically a rectangular lattice. A given image projected by each light source module is divided into (m-1)*(n-1) lattice regions, and the four corners of each lattice region are represented as projected identification points, i.e., m*n projected identification points. Furthermore, there are overlapping regions between the widths of the projected images of adjacent light source modules, and the size of the overlapping regions is an integer multiple of the lattice region in the corresponding direction. Projected identification points may overlap in the junction regions between adjacent light source modules. The overlapping (junction) direction includes the horizontal and / or vertical directions of the m*n projected identification dot matrix. In other words, at the horizontal edge of the standard projected image of each light source module, an integer number of rows of projected identification points overlap with the projected identification points of another horizontally adjacent light source module, and simultaneously or non-simultaneously, at the vertical edge of the standard projected image of each light source module, an integer number of columns of projected identification points overlap with the projected identification points of another vertically adjacent light source module. The projection overlap area of ​​each light source module includes overlap areas in one, two, three, or four directions.

[0076] The optical orientation process (also called orientation work) is performed by projecting a standard projection image onto each light source module independently. Refer to Fig. 7. In this embodiment, the orientation of multiple light source modules is performed based on the same orientation plate. Preferably, the orientation plate is placed on the printing surface and does not move. A plurality of orientation areas are defined on the orientation plate corresponding to each light source module, and the projected identification points of each light source module correspond one-to-one to the identification points in the orientation area corresponding to the light source module. It can be seen that there is a joint area between the orientation areas of adjacent light source modules.

[0077] Referring to FIG. 10, it shows a schematic diagram of obtaining pitches based on the same coordinate system of projected identification points and orientation identification points, and the steps include:

[0078] In S1010, an image of the projection area is acquired; Specifically, a target plate is placed on the printing surface, and a target area is defined on the target plate corresponding to the light source module of the target. The light source module of the target is installed to project a standard projection onto the target area (also called the projection area) of the target plate, and projected identification points are provided on the target projection. The image of the projection area can be acquired by using any image acquisition device. A photographed image of the printing surface (i.e., the projection area) is acquired, and the photographed image includes the projected identification points and the target identification points.

[0079] In S1020, a projection discrimination point matrix and an orientation discrimination point matrix are constructed based on the projection discrimination points and the orientation discrimination points in the image; In S1030, the projected discrimination point matrix and the orientation discrimination point matrix are transformed into the same coordinate system, and the pitch of the projected discrimination points and the orientation discrimination points based on the same coordinate system is calculated.

[0080] Specifically, the projection point matrix and / or the orientation point matrix are rotated and translated, and then the pitch of the projection identification points and the orientation identification points in the image coordinate system is calculated. The same coordinate system is the image coordinate system.

[0081] In this embodiment, before converting the pitch into an offset amount in the pixel coordinate system, the rotated and translated orientation point matrix and projection point matrix are first determined, P'1=R1P1, P'2=R2P2 Here, P'1 is the orientation discrimination point after rotation, P'2 is the projected discrimination point after rotation, and R1 and R2 are both rotation matrix parameters.

[0082] The principle of the rotation operation is as follows.

number

[0083] The corresponding matrix operation method is as follows:

number

[0084] where:

number

[0085] In the rotation operation, the deflection angle θ can be calculated by taking a diagonal point, a horizontal point, or a vertical point to calculate the included angle (corresponding to taking a diagonal line, a horizontal line, or a straight line, and calculating the deflection angle of a line segment).

[0086] After the rotation operation is completed, calculate the pitch value T0. The calculation method for T0 is P'2-P'1-T', which represents the pitch value in the image coordinate system of the orientation identification point and the projected identification point, and obtain the following T0 matrix.

number

[0087] T' is taken from the region with the least distortion (currently the middle region defaults to having the least distortion, but of course you can do a least squares fit to find the region with the least actual distortion). Subtracting T' is equivalent to translating the matrix.

[0088] Next, it is necessary to associate each parameter in the T0 matrix with the pixel coordinate system. In this embodiment, the result T'0 (i.e., the target matrix) can be obtained through fitting operation, and the size of the matrix is ​​consistent with the size of the image resolution, and the result is stored by calculating the offset amount of all pixel points in the image.

number

[0089] For example, combining the resolution situation of currently available light source modules on the market, j×k may be 1920×1080, 2560×1440, 3840×2160, etc.

[0090] Finally, the position information of all pixel points in the image in pixel coordinates can be calculated, that is, C1=C0+T'0P'. where:

number

[0091] After completing the orientation for all light source modules, the position information of the pixel points in all the orientation areas can be obtained;

number

[0092] The projection area of ​​each light source module uses the target point on the target plate as the reference coordinate system, and after targeting, each projected target point coincides with the coordinate of the target point. Because one target plate is shared, the light source module areas can be joined at the sub-pixel level after targeting.

[0093] Please refer to FIG. 11, which shows a schematic diagram of the projection method, which includes:

[0094] In S1110, a division process is performed on the slice image to be projected based on the projection area of ​​each light source module, to obtain a plurality of divided images; Specifically, each divided image includes a joint overlap region that is shared with an adjacent divided image. The divided images and the projection region may be the same size.

[0095] In S1120, the image information is gradually changed in the overlapping regions of the divided images, and the processed divided images are transmitted to the corresponding light source modules, where each light source module is obtained by the orientation method described above. The image information is used to detect image features, and can be expressed in matrix form, such as grayscale, illuminance, light intensity, and other related parameters.

[0096] Specifically, the image decomposition boundary can be set according to the orientation identification point of the joint area edge; Based on the image division boundary, gradation processing is performed on the edge of the projected image of each optical unit, and the image information of the projected image in the overlapping area of ​​each optical unit is gradually changed in a stepwise manner. For example, the image information value gradually decreases in the direction approaching the edge of the joining area (from the inside of the divided image to the edge side), and gradually increases in the direction approaching the edge of the joining area, conforming to a gradual change formula. Note that the gradual change is not limited to gradual increase or decrease, and other gradual change formulas may be used. The above two types of gradual change formulas are used for illustrative purposes only.

[0097] In one specific example, the step of performing image information gradual change processing on the overlapping region of the divided images includes the steps of performing image processing on the overlapping region of one of the divided images, dividing the overlapping region into several sub-regions based on the image information, and ensuring that the overlapping value of the image information in the sub-region of each divided image is within a predetermined range.

[0098] Specifically, the overlapping area is divided into several sub-areas, and for the N divided images to be joined, any sub-area overlaps with a corresponding sub-area in all of the divided images. The overlapping values ​​of the image information of the N overlapping sub-areas of the N divided images are within a predetermined range. The predetermined range may include multiple values, or it may be only one value. Taking the gradation of an 8-bit image as an example, the overlapping gradation value may be set between 0 and 255, or may be set to a value greater than 255, such as 260. Setting the overlapping gradation value greater than 255 can further reduce the impact of the interval between light-on times on the joining. The above projection method divides the entire projected image as needed according to the orientation standard, performs algorithmic processing on the divided image edges, optimizes the positioned sub-pixel level defects, and smoothly transitions the printing of the joined and non-joined areas, achieving a traceless joining effect.

[0099] In one specific example, when the number of light source modules corresponding to the joint overlapping region is a first predetermined number, the image information value of any joint overlapping region decreases stepwise along a first direction and remains unchanged along a second direction, the first direction is a joint direction of the divided images and is a direction from the inside to the edge side of the divided images, and the first direction is perpendicular to the second direction; When the number of light source modules corresponding to the overlapping area is a second predetermined number, the image information value of any overlapping area decreases stepwise along the first direction, where the second predetermined number is greater than the first predetermined number.

[0100] Here, the two divided images overlap along the joining direction, forming a joining overlap region.

[0101] Specifically, the number of light source modules corresponding to a spliced ​​overlapping region is the number of light source modules projected onto the spliced ​​overlapping region. When one-dimensional splicing is performed, the number of light source modules corresponding to the spliced ​​overlapping region is two. When two-dimensional splicing is performed, there are spliced ​​overlapping regions with a corresponding number of four light source modules and spliced ​​overlapping regions with a corresponding number of two light source modules. The first predetermined number may be two, and the second predetermined number may be four.

[0102] When the number of light source modules corresponding to the overlapping area is a first predetermined number (e.g., two), that is, when the overlapping area corresponds to two divided images, these two divided images are referred to as the first and second divided images for ease of explanation. When the first divided image is relatively on the left side and the second divided image is relatively on the right side, the overlapping area of ​​the images is located on the right side of the first divided image and the left side of the second divided image, respectively. The joining direction is horizontal (from left to right or right to left), and the direction from the inside of the divided image to the edge side is joined, and the first direction is from left to right. For the first divided image, the image information value of the overlapping area gradually decreases from left to right (from the inside of the divided image to the edge side). For the second divided image, the image information value of the overlapping area gradually decreases from right to left (from the inside of the divided image to the edge side). Note that the decrease does not necessarily have to be a strict monotonic decrease, but rather it is sufficient to satisfy the decrease. By performing bonding using this method, the influence of misalignment of the bonding can be reduced.

[0103] When the number of light source modules corresponding to the overlapping region is a second predetermined number (e.g., four), that is, the overlapping region corresponds to four divided images. For convenience of explanation, the four divided images are named the third, fourth, fifth, and sixth divided images. If the third divided image is located in the upper left, the fourth divided image is located in the upper right, the fifth divided image is located in the lower left, and the sixth divided image is located in the lower right, the overlapping region is located in the lower right of the third divided image, the lower left of the fourth divided image, the upper right of the fifth divided image, and the upper left of the sixth divided image. The first direction may be two directions. For the third divided image, the joining direction is the horizontal direction and the vertical direction, combining the direction from the inside to the edge of the divided image, and the first direction is from top to bottom and from left to right. Therefore, the image information value of the overlapping region of the third divided image gradually decreases from left to right and from top to bottom. Similarly, the image information value of the overlapping area of ​​the fourth divided image decreases in steps from right to left and top to bottom, the image information value of the overlapping area of ​​the fifth divided image decreases in steps from left to right and bottom to top, and the image information value of the overlapping area of ​​the sixth divided image decreases in steps from right to left and bottom to top.

[0104] In one specific example, the change trend of the first image information distribution and the change trend of the second image information distribution exhibit a mirror image relationship or an approximate mirror image relationship, the first image information distribution is the image information of the overlapping area of ​​one of the divided images in adjacent divided images, and the second image information distribution is the image information distribution of the overlapping area of ​​another of the divided images in the adjacent divided images, and the inversion axis of the mirror image relationship is determined based on the position of one of the divided images and the position of the other divided image.

[0105] Specifically, taking left and right mirror images as an example, when the change trend of the first image information distribution on the left side changes from large to small, the change trend of the second image information distribution on the right side changes from small to large. The approximate mirror image relationship means that the change trends may partially exhibit a mirror image relationship, but may not partially exhibit a mirror image relationship, and may not necessarily be a strict mirror image relationship.

[0106] Furthermore, the first image information and the second image information have a mirror image relationship or an approximate mirror image relationship, where the first image information is image information of a joint overlapping region of one of the divided images in adjacent divided images, and the second image information is image information of a joint overlapping region of another of the adjacent divided images, and the inversion axis of the mirror image relationship is determined based on the position of one of the divided images and the position of the other divided image. The approximate mirror image relationship means that the change tendency may partially exhibit a mirror image relationship and partially not exhibit a mirror image relationship, and may not be a mirror image relationship in the strict sense.

[0107] In one example, the image information is expressed as grayscale, the light source modules are at least two, and the projection method specifically includes: providing a physical connection to the light source module; performing optical orientation for each light source module using an orientation plate, the orientation plate including an orientation identification point; performing a splice overlap orientation inspection for each optically aligned light source module; and decomposing the overall projection image to obtain a plurality of projection partial views corresponding to the number of light source modules, and then performing gradation gradation processing on the joint area of ​​each projection partial view, which specifically includes the steps of: setting an image decomposition boundary based on the orientation discrimination point of the joint area edge; and performing gradation processing on the projected image edge of each light source based on the image decomposition boundary, so that the gradation of the projected image in the joint area of ​​each light source module gradually decreases in the direction approaching the joint area edge.

[0108] The entire image is divided and an image decomposition boundary is determined based on the coordinates of the orientation point of the edge of the junction area. The image edges of each optical projection are processed from the image decomposition boundary. A stepwise gradation calculation is performed for the pixel projection of the junction area. The gradation of each optical projection area decreases (e.g., monotonically or non-monotonically) from the center to the edge. The gradient overlap during the decrease (i.e., the gradient value is overlapped at each decrease, and the gradient is not cleared but continuously overlapped) is satisfied. The gradient overlap value can be a fixed value or within a certain range of values. For example, for an 8-bit image, if the fixed value is 255, the gradient value after the gradient overlap can be 250. For the final printing effect, the gradient values ​​can be 250, 255, or 253. The processed image is then properly joined and processed by the host computer through image processing hardware and distributed to each designated optical projection.

[0109] After each light projection is processed through the above steps, the projection images of each light source module can be fused into one large-area projection image that matches the initial projection image.

[0110] In one specific embodiment, the step of performing gradation processing on each illuminator projected image edge based on the image decomposition boundary includes: obtaining a first pixel tone distribution from the inside to the outside of a projected image in a joint area of ​​each optical unit and a second pixel tone distribution from the inside to the outside of a projected image in a joint area of ​​an adjacent optical unit; The method includes determining a gradation overlap value of an overlapping area of ​​adjacent optical devices based on the first pixel gradation distribution and the second pixel gradation distribution, and performing defect correction on the projected image of each optical device based on the gradation overlap value.

[0111] In this embodiment, a pixel point in column a and row b is set at the matrix boundary of each optical device to form a joining region.

[0112] If any of 1, a, and b is 0, the projection junction of each optic is a one-dimensional junction, i.e., the projection area of ​​each optic has a column or b rows of overlap with the projection area of ​​another adjacent optic.

[0113] When b=0, the maximum gradation of the printing exposure is u, and the pixel gradation distribution from the inside to the edge of the projection area of ​​each optical device (i.e., the first pixel gradation distribution) is a={a1,a2,...,a a-1 ,a a} and u≧a≧0 a approximates a decreasing sequence.

[0114] The projection edge of the adjacent optical device has a pixel tone distribution from the inside to the edge (i.e., the second pixel tone distribution). a'={a a ,a a-1 ,...,a2,a1}, The gradation overlap value of the overlap region is p, i.e., p=a+a', and the value of p is set according to the actual printing process.

[0115] On the other hand, the value of p can be a fixed value, and the light intensity of the non-bonded area is set as q, where q+v≧p≧qv, and v selects the influence of the actual printing effect according to the difference in the gradation value. In other words, p can be directly equal to the light intensity of the non-bonded area q, or it can be slightly larger or smaller than q.

[0116] On the other hand, p does not have to be a fixed value, and may be multiple values, but the range of values ​​p can take is q+v≧p≧qv, and v selects the degree of influence of the actual printing effect according to the difference in gradation value. In other words, p is a value that varies within a certain range, but in actual printing molding, differences in p do not significantly affect the consistency of the printing effect.

[0117] This edge processing method can make the light intensity of the bonded area match or approximate the light intensity of the non-bonded area, thereby reducing the print bond marks and the effects of misalignment of the bond.

[0118] In the overlapping area, an offset occurs in the same direction as the a-array due to the junction, i.e., in the junction area, A={a1,a2,...,a a-1}, and u≧A≧0, and A approximates an arithmetic decreasing sequence, A'={a a-1 ,...,a2,a1}.

[0119] The gradation overlap value of the overlapping area changes, P = A + A'. That is, p changes by about a2 - a1, while the gradation of the non-overlapping area changes by a a increases.

[0120] The number of terms in the sequence a is sufficiently large and a a When is sufficiently small, one pixel is offset in the same direction as the a array, and if the effect on the gradation superimposition value is not large, it is considered that there is no effect on the set gradation superimposition value P.

[0121] When P=260 is set, the width surface A and the width surface B are joined, the pixel arrangement of the width surface A is an arithmetic progression from left to right, and the pixel arrangement of the width surface B is an arithmetic progression from right to left, and after the overlapping, the gradation harmony is 260, there is a 1 pixel shift in the horizontal direction, and the difference between the maximum gradation overlap value of the joining area and the pixel gradation of the normal area is only the tolerance.

[0122] Similarly, when P=15 or 16 is set, the width surface A1 and the width surface A2 are joined horizontally, the pixel arrangement of the width surface A1 is an arithmetic progression from left to right, and the pixel arrangement of the width surface A2 is an arithmetic progression from right to left, and after superposition, the gradation harmony is 15 or 16, with a one-pixel position shift in the horizontal direction, and the difference between the gradation superposition value of the joining area and the pixel gradation 15 or 16 of the normal area is not large.

[0123] In the overlapping area, a vertical offset occurs between one pixel and the a array due to the joining, that is, the overlap of the edge pixels in the vertical direction of the joining area changes, while the non-edge pixels remain consistent and unchanged. Then, the distribution of the edge pixels in the vertical overlapping area is as follows: A"={a1,a2,...,a a-1 ,a a}, and u≧a≧0, approximates an arithmetic progression, A"'={0,0,...,0,0}, P'=A"+A"'=A".

[0124] In this case, P' is expressed as a gradient-approximating gradational gradient sequence, and in the macroscopic image it is expressed as a one-pixel-wide diagonal line, with a gradual transition of one pixel offset in the vertical direction, resulting in a smooth transition without any noticeable steps after printing.

[0125] When a single pixel is offset vertically at the joint, a natural grayscale line transition appears. Corresponding to real 3D printing, a smooth diagonal line is formed at the pixel offset, and no obvious joint marks appear.

[0126] 2. If neither the pixel point in column a nor row b is zero, the projection junction of each light source is a two-dimensional junction, i.e., the projection area of ​​each light source overlaps with other adjacent single light sources by a and b. The overlap of the projection edge of each light source with the edge of an adjacent single light source is similar to the effect of the one-dimensional overlap described above, and when overlapping with an adjacent corner, the corner contains the corner overlap of four single light sources.

[0127] The pixels in the four corner overlapping areas are rectangular areas, and the pixel settings within the area are simultaneously affected by the a-row, b-column arithmetic progression setting, and are set to a pixel group of e-row, f-column based on the number of pixels. The gradation between adjacent pixels is approximated by the arithmetic value c, and the expected gradation overlap value within a single width plane is P1, forming a pixel gradation arrangement as shown in Table 1. [Table 1]

[0128] In Table 1, c=P / (e+f-1) is an integer value, so the value of c can be adjusted appropriately to change and compensate for the differences in some items in the sequence, and the sequence will approximate an arithmetic progression.

[0129] After the pixel tones at the four corners are superimposed, the distribution of the tone values ​​within the region is about 2P, as shown in Table 2. [Table 2]

[0130] During projection, the gradation overlap value P1 within the region within a single width is set to half the gradation overlap value p of the overlapping region, i.e., p = 2P1, so that the overlap value of the joining region can be kept constant at p. The gradation distribution within the region satisfies a two-dimensional approximate arithmetic distribution. Similar to a one-dimensional joining change, this arrangement method can reduce the impact of misalignment.

[0131] For example, if a printed image is to be split into four pieces and then joined together, the initial resolution is first disassembled and divided into 1, 2, 3, and 4 images. The edges of the images undergo the above-mentioned gradual change processing, and each is sent to the corresponding single-width optical system, ultimately displaying an image that matches the initial projected image.

[0132] Please refer to FIG. 12, which shows a schematic diagram of slicing a three-dimensional data model, specifically: In S1210, performing a slice process on the three-dimensional data model to obtain several slice images; In S1220, the method includes a step of sequentially executing any one of the above projection methods for each slice image according to a predetermined projection order of the slice images.

[0133] In one embodiment, a flowchart of a 3D printing method is provided, specifically: the step of physically joining the light source modules; the step of optically aligning each light source module using an alignment plate, the alignment plate including alignment identification points; the step of performing alignment inspection of the spliced ​​overlap of each optically aligned light source module; the step of performing defect correction on the projected image of each light source module based on the alignment inspection result; the step of performing slicing processing on the three-dimensional data model to obtain N slice layer images, where N>1; the step of decomposing each slice layer image to obtain M slice layer sub-images, and then performing gradation change processing on the joining area of ​​each slice layer sub-image; the step of obtaining M corresponding slice layer sub-images for each slice layer image, and controlling each light source module to project them onto the molding interface based on each slice layer sub-image, causing a crosslinking reaction in the photo-curable material, thereby obtaining cured layers corresponding to each slice layer image; and the step of accumulating the cured layers layer by layer to obtain a three-dimensional entity corresponding to the three-dimensional data model.

[0134] An embodiment of the present invention further discloses a wide-surface joining system that realizes 3D printing, where the joining system is based on a 3D printing method, and the joining system includes a physical joining debugging system, a single orientation system, and a display algorithm system.

[0135] Here, the physical bonding debugging system is composed of a physical adjustment structure and a width surface alignment tool. In the 3D printing-based platform, the physical adjustment structure adjusts the spatial position of the single width surface exposure unit, and with the assistance of the width surface alignment tool, all the single width surface exposure units are bonded together, with a bonding accuracy of within 10 pixels (within approximately 1 mm), forming a combined width surface in which the difference in bonding cannot be distinguished with the naked eye, and a bonding overlap area 600 exists on the combined width surface, as shown in Figure 13.

[0136] The light source module to be aligned projects an ideal projection image onto the projection platform. The light source module may be installed on the top or bottom of the projection platform, and is not limited thereto. The ideal projection image is a dot matrix image composed of ideal projection points. A corresponding dot matrix image is also installed on the alignment plate, which is a dot matrix image composed of alignment points. However, the projection points (including ideal projection points and actual projection points) are different from the reference points, and "different" may refer to differences in color or shape. In this embodiment, in a picture captured by a camera, the projection points are displayed as white points and the reference points are displayed as black points, which helps to distinguish the reference points from the projection points.

[0137] It should be noted that the shape, number, and size of the sampling points (including the reference points and the projection points) can be set according to needs and are not limited in this embodiment. The sampling points may be easily identifiable patterns such as squares, circles (i.e., dots), triangles, and polygons. After the guide plate is placed, the camera photographs the projection platform and captures the guide plate and the actual projection. The actual projection is distorted in a barrel shape compared to the ideal projection. In the image captured by the camera, the center of the guide plate and the center of the actual projection do not overlap, and the guide plate and the actual projection are misaligned, and some or all of the projection points may not overlap with the reference points.

[0138] In a preferred solution, to ensure the clarity of the image, the camera can take multiple clear pictures using multiple shooting methods to capture all projection points and reference points. After shooting, the orientation module processes the images, identifies the orientation points and projection points, and obtains the coordinates of the orientation points and projection points. The single orientation system may be a standalone device independent of the 3D printer, or may be composed of a set of orientation assembly and some components of the 3D printer. For example, the set of orientation assembly may include a camera, an orientation plate, and an orientation module, and the projection platform may be a light-transmitting plane installed on the frame of the 3D printer or the bottom of the tray of the 3D printer.

[0139] In one embodiment, as shown in FIG. 14, an orientation device for joining light source modules is provided, which includes at least two light source modules, and an orientation device for performing optical orientation processing on each light source module, where a joining overlap area exists in the projection area of ​​each light source module, and a verification device for performing orientation accuracy inspection on each light source module that has been optically positioned in the joining overlap area.

[0140] In one embodiment, a three-dimensional printer is provided, comprising a memory and one or more processors, the memory having computer-readable instructions stored therein, the processors performing the steps of any of the methods described above when executing the computer-readable instructions.

[0141] In one embodiment, a non-volatile computer-readable storage medium is provided having computer-readable instructions stored thereon that, when executed by a processor, implement the steps of any of the above methods.

[0142] It should be understood that, although the steps in the above flowcharts are sequentially indicated by arrows, these steps are not necessarily performed sequentially in the order indicated by the arrows. The execution of these steps is not limited to a strict order and may be performed in other orders unless explicitly stated otherwise in this specification. Furthermore, at least some of the steps in the figures may include multiple substeps or multiple stages, and these substeps or stages do not necessarily need to be performed and completed at the same time but may be performed at different times. The execution order of these substeps or stages does not necessarily need to be sequential, and they may be performed alternately or alternately with other steps or at least some of the substeps or stages of other steps. Each embodiment in this specification is described sequentially, and each embodiment mainly describes the differences from other embodiments. The same or similar parts between the embodiments may be mutually referenced. Since the systems disclosed in the embodiments correspond to the methods disclosed in the embodiments, the description is simple, and relevant reference may be made to the description of part of the method. It should be noted that those skilled in the art can further make some improvements and modifications to the present application without departing from the principles of the present application, and these improvements and modifications also fall within the scope of protection of the claims of the present application.

[0143] It should be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another and do not require or imply the existence of any such actual relationship or order between those entities or operations. Furthermore, the terms "comprise," "contain," or any other variation thereof are intended to include a non-exclusive inclusion, whereby a process, method, article, or device that includes a set of elements not only includes those elements, but also includes other elements not expressly listed or that are inherent in such process, method, article, or device. Absent more limitations, an element qualified by the phrase "comprises one ..." does not exclude the presence of additional identical elements in the process, method, article, or device that includes the element. [Industrial Applicability]

[0144] The solution provided in the embodiment of the present invention can be applied to the field of 3D printing technology. In the embodiment of the present invention, optical orientation processing is performed for each light source module, and a splicing overlap area exists in the projection area of ​​the optically aligned light source module. Based on the splicing overlap area, orientation accuracy testing is performed for each optically aligned light source module. The embodiment of the present invention can avoid the occurrence of splicing lines and pixel information distortion during joining, thereby solving the problem of joining defects caused by joining light source modules and improving the projection effect and 3D printing effect.

Claims

1. A method for locating a light source module joint, comprising: The light source module includes at least two light source modules, and the method includes: a step of performing optical orientation processing on each of the light source modules, wherein a spliced ​​overlap area exists in the projection area of ​​the optically-oriented light source module; and performing a splice orientation accuracy inspection for each optically aligned light source module based on the splice overlap area; The orientation method further comprises: adjusting the light projection width of the optically aligned light source module so that the deflection angle and offset amount of each of the light projection widths based on the reference width meet a first predetermined requirement; The first predetermined requirement includes that the difference between the deflection angles of each of the projection width surfaces based on the reference width surface is within a first predetermined range, and the difference between the offset amounts of each of the projection width surfaces based on the reference width surface is within a second predetermined range.

2. Before performing optical orientation processing on each of the light source modules, 2. The method for locating a light source module joint as claimed in claim 1, further comprising the step of physically joining each of the light source modules so that the projection area of ​​each of the light source modules meets the requirement of a predetermined projection width surface.

3. The step of physically joining each of the light source modules includes:

3. The method for locating light source modules as described in claim 2, further comprising a step of adjusting the horizontal position of each of the light source modules so that the pitch between the boundary of the first feature image of the light source module and the bezel of the locating tool satisfies a first predetermined distance, and the pitch between the second feature image projected by each of the light source modules and the auxiliary image satisfies a second predetermined distance, wherein the locating tool is provided on a printing surface and the auxiliary image is provided on the locating tool.

4. Before adjusting the horizontal position of each of the light source modules, 4. The method for locating light source module joints according to claim 3, further comprising a step of adjusting the horizontality of each of the light source modules relative to the printing surface and the vertical distance between each of the light source modules and the printing surface, so that the light projection width of each of the light source modules reaches a predetermined dimension.

5. A step of inspecting the orientation accuracy of the spliced ​​overlap for each optically aligned light source module. teeth, a step of acquiring a first current position of a projected feature point and a first standard position corresponding to the projected feature point, the projected feature point being formed by projecting each of the optically oriented light source modules onto a printing surface, an orientation tool being provided on the printing surface, and an orientation identification point being provided on the orientation tool for characterizing the first standard position; determining a deflection angle and an offset amount corresponding to each optically located light source module based on the first current position and the first standard position; 2. The method for locating a light source module as claimed in claim 1, further comprising: a step of determining that the location is successful if each of the deflection angles and each of the offset amounts satisfies a second predetermined condition, wherein the second predetermined condition includes a deviation between each of the deflection angles being within a third predetermined range and a deviation between each of the offset amounts being within a fourth predetermined range.

6. The step of inspecting the orientation accuracy of the spliced ​​overlap of each optically aligned light source module includes: a step of acquiring a second current position of the overlap projection feature point and a second standard position corresponding to the overlap projection feature point, the overlap projection feature point being obtained by projecting each light source module that has been optically oriented onto the joint overlap area, wherein an orientation tool is provided on the printing surface, and an orientation identification point for characterizing the second standard position is provided on the orientation tool; 2. The method for positioning a light source module joint according to claim 1, further comprising: a step of determining that the positioning is successful if the deviation value between the second current position and the second standard position satisfies a second predetermined condition.

7. The step of performing optical orientation processing for each of the light source modules includes: Using an orientation tool located in the same coordinate system to perform an optical orientation process for each of the light source modules, or 2. The method for joining light source modules according to claim 1, further comprising a step of employing the same positioning tool to perform optical positioning processing on each of the light source modules, wherein the coverage area of ​​the positioning tool is greater than or equal to the projection width surface obtained by joining each of the light source modules.

8. The step of performing optical orientation processing for each of the light source modules includes: A step of acquiring pitches based on the same coordinate system of the projected identification points and the orientation identification points, The projected identification point is obtained by projecting a predetermined image onto a corresponding projection area using the light source module, and an orientation tool is provided in the corresponding projection area, and an orientation identification point is provided on the orientation tool; 2. The method for locating a light source module joint according to claim 1, further comprising the step of: locating each of the light source modules based on the pitch.

9. The step of acquiring pitches based on the same coordinate system of the projected identification points and the orientation identification points includes: acquiring an image of the projection area; constructing a projected discrimination point matrix and an oriented discrimination point matrix based on the projected discrimination points and the oriented discrimination points in the image; converting the projected discrimination point matrix and the orientation discrimination point matrix into the same coordinate system, and calculating pitches of the projected discrimination points and the orientation discrimination points based on the same coordinate system; and The step of orienting each of the light source modules based on the pitch includes:

9. The method for locating a light source module joint according to claim 8, further comprising converting the pitch into an offset amount in a pixel coordinate system, and locating each of the light source modules based on the offset amount.

10. The step of converting the pitch into an offset amount in a pixel coordinate system includes: constructing a corresponding pitch value matrix based on the pitch, and associating each parameter in the pitch value matrix with a pixel coordinate system; performing a fitting operation on the pitch value matrix to obtain a target matrix; 10. The method for locating a light source module joint according to claim 9, further comprising: a step of obtaining the offset amount based on the target matrix, element coordinate position information of the pixel coordinate system, and physical dimensions corresponding to a unit pixel point.

11. In the step of obtaining the offset amount, the offset amount is obtained by the following formula: C １ =C ０ +T' ０ P' Here, C １ is the offset amount, and C ０ is the element coordinate position information, and T' ０ 11. The method of claim 10, wherein P' is the target matrix, and P' is a physical dimension corresponding to a unit pixel point.

12. The alignment method for joining a light source module according to any one of claims 1 to 11, wherein the light source module is any one or any combination of a DLP projection module, an LCD projection module, an LCOS projection module, an OLED projection module, a Micro-led module, a Mini-led module, an LCD module, an OLED module, and an SXRD projection module.

13. The step of inspecting the orientation accuracy of the splice and overlap for each optically aligned light source module based on the splice and overlap area includes: determining the orientation accuracy based on the overlapping projected feature points in the joint overlapping area of ​​each light source module or the gap between the projected feature points and the standard points; determining the orientation accuracy based on the deviation between the center coordinates of the overlapped projection feature points and the photolithography points in the orientation tool; determining the orientation accuracy based on the shape of each of the overlapping projected feature points; or determining the orientation accuracy based on the overlapping ratio of the projected feature points; Also includes one 2. The method for locating a light source module joint according to claim 1, further comprising the step of performing optical locating processing on each of the light source modules if the locating accuracy test is unsuccessful.

14. Obtaining an aligned light source module using the alignment method for joining a light source module according to claim 1; performing a division process on the slice image to be projected based on the projection area of ​​each light source module to obtain a plurality of divided images; A projection method characterized by including a step of performing gradation processing of image information on the overlapping areas of the divided images and transmitting the processed divided images to corresponding light source modules, wherein the image information includes one of illuminance, light intensity, and gradation.

15. The step of performing gradual variation processing of image information on the overlapping regions of the divided images includes: The projection method of claim 14, further comprising a step of performing image processing on a joint overlap region of one of the divided images, dividing the joint overlap region into several sub-regions based on image information, and ensuring that the overlap value of the image information in the sub-region of each of the divided images is within a predetermined range.

16. When the number of light source modules corresponding to the spliced ​​overlapping regions is a first predetermined number, the image information value of any of the spliced ​​overlapping regions decreases stepwise along a first direction and remains unchanged along a second direction, the first direction being a splicing direction of the divided images and a direction from the inside of the divided images to an edge side, and the first direction being perpendicular to the second direction; 16. The projection method of claim 15, wherein when the number of light source modules corresponding to the overlapping region is a second predetermined number, the image information value of any of the overlapping regions decreases stepwise along the first direction, and the second predetermined number is greater than the first predetermined number.

17. performing a slicing process on the three-dimensional data model to obtain a number of slice images; and sequentially executing the projection method of claim 14 on each of the slice images in accordance with a projection order of the predetermined slice images.

18. 10. A three-dimensional printer comprising a memory and one or more processors, the memory having computer-readable instructions stored therein, the processors performing the steps of the method of claim 1 when executing the computer-readable instructions.

19. 15. A three-dimensional printer comprising a memory and one or more processors, the memory having computer-readable instructions stored therein, the processors performing the steps of the method of claim 14 when executing the computer-readable instructions.

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