Market Application Background
Laser galvanometer control systems are ideal for high-speed micromachining applications, such as laser marking, welding, 3D printing, and precision cutting, due to their advantages of low inertia, low load, and extremely fast response speed.
The laser galvanometer control system mainly encompasses two technical aspects: laser galvanometer control and pattern correction, which together control the precision of laser guidance during processing. The laser galvanometer control system uses high-speed deflecting mirrors to change the direction of the laser, dynamically focusing it onto any working position within the field of view and processing along a predetermined trajectory, thus achieving high-precision laser processing.
In actual production processes, the laser galvanometer scanning process is affected by various factors such as optical and physical characteristics, which leads to inherent nonlinear errors in the scanning field, causing distortion of the processed pattern, affecting the quality of the final product, and resulting in a series of problems such as increased defect rate and high rework costs, which are detrimental to the profitability of enterprises. Therefore, galvanometer correction is necessary.
Limitations of traditional galvanometer correction methods:
Existing traditional scanning galvanometer calibration methods typically employ Box coefficient calibration or multi-point calibration, requiring manual measurement and recording of the comparison between theoretical and actual measurement data.
As the precision requirements of laser processing increase, the spacing and number of scanning points that need to be measured also increase exponentially. This results in the need for multiple superimposed measurements during the calibration process, leading to low efficiency and accuracy of galvanometer calibration. The calibration process is cumbersome and time-consuming, often failing to meet the application needs of the high-speed and high-precision laser processing market.
Positive motion technology solutions:
To address the above industry pain points, Zheng Motion Technology has launched a high-precision galvanometer vision correction solution based on a laser galvanometer motion controller. Through machine vision correction and compensation, the accuracy of the galvanometer laser processing system can be significantly improved.
By using a motion control platform with corrected compensation and CCD image acquisition coordinates, it can automatically locate and acquire multi-point data marked by the galvanometer. By using a multi-point galvanometer correction algorithm with positive motion, a high-precision correction file can be quickly generated. The angle of the galvanometer can be adjusted accordingly to correct these inherent deviations, which can effectively improve the correction accuracy and efficiency.
01. High-precision galvanometer vision correction solution for laser galvanometer motion controller
Schematic diagram of laser galvanometer control system processing
Pain points of galvanometer calibration solutions on the market
Manual measurement and correction of data results in large errors and low efficiency.
High-precision two-dimensional measuring instruments are expensive and complex to operate.
• Software integration is difficult and does not support secondary development.
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Design of a positive motion galvanometer correction solution
1. Demonstration of positive motion vision correction software
(1) Operation procedure:
(2) Comparison of calibration results:
Before galvanometer calibration
After galvanometer calibration
The comparison results of the two laser galvanometers before and after calibration show that the error values of most points are relatively large without galvanometer calibration, around ±0.5mm, while the error after calibration is significantly smaller, with the error values of most points controlled within ±0.005mm.
This demonstrates that the high-precision galvanometer vision correction solution using a laser galvanometer motion controller with positive motion technology greatly improves processing accuracy.
2. Core Technological Advantages of the Solution
• Supports platform pitch compensation; two-dimensional compensation algorithm improves accuracy.
• Automatic calibration of test data improves calibration efficiency and accuracy.
• The software interface (API) is open, facilitating rapid secondary software development, integration, and customization.
• Integration of laser control, galvanometer control, motion control, and machine vision accelerates software development.
3. Hardware Configuration of the Solution
4. Customer Benefits
• The calibration process has been simplified, calibration time has been reduced by 30%, and production efficiency has been significantly improved.
Automated processes reduce human intervention, significantly lowering labor and time costs.
A unified API function interface is compatible with various high-level programming languages for PCs, simplifying the system integration and application development process for engineers.
The motion control and laser process controller's internal embedded system interacts in real time, reducing the need for PC-based computation and improving system response speed and operational accuracy to the micrometer level. This results in a more than 10% improvement in processing efficiency and precision, effectively reducing the scrap rate.
02
ZMC408SCAN-V22 Open-type laser galvanometer motion controller
The stand-alone laser galvanometer motion controller integrates laser control, galvanometer control, and bus axis/pulse axis control, helping you achieve a highly efficient and precise EtherCAT bus motion control + laser galvanometer solution.
• Optional 6-64 axis motion control (pulse + EtherCAT bus)
• 2-channel laser galvanometer interface with feedback, 1-channel LASER and 1-channel FIBER dedicated laser power supply interface
Supports 1D/2D/3D PSO functions, enabling visual aerial photography, precision dispensing, and laser energy control.
The integration of laser galvanometer control and motion control allows for the flexible construction of laser processing systems with multi-axis linkage and other configurations.
• Multi-dimensional position synchronization output (PSO), onboard 24 general-purpose inputs and 20 general-purpose outputs, including 4 high-speed color mark latches, 4 PSOs and 8 PWM outputs.
