Abstract
The multi-axis laser manufacturing equipment is a piece of standard equipment suitable for complex components with hard and brittle material. The laser beam direction inevitably deviates from the coordinate axis of equipment due to the location of laser and optical parts, leading to component’s substrate over-cutting. This paper proposes a compensation method for the laser beam deflection to enhance the accuracy of the laser manufacturing. The deflection measurement was achieved by image and point cloud processing. The proposed method scans the point cloud model and fits the geometric feature to realize the orientation of the laser collimator relative to the equipment. The error of laser beam deflection calculates by the orientation of collimator and the spatial geometric relationship of the displacement and the laser trajectory. An error compensation model is constructed to compensate for dynamic error in the whole motion range during the calculation of equipment motion. The effectiveness of this method is verified through laser beam measurement, compensation and laser manufacturing for a complex component. The results show that the proposed method improves the processing accuracy (91.6 μm versus 316.6 μm) by data statistics.
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Abbreviations
- \(M_{c}\) :
-
The calibration relationship between the 3D scanner and the laser equipment.
- \(Pc_{i}\) :
-
Each point in the scanned point cloud model of the collimator.
- \(Pc^{\prime}_{i}\) :
-
The transformed point coordinate of \(Pc_{i}\).
- \(V_{d}\) :
-
The center axis of the cylindrical surface.
- \(V_{p}\) :
-
The normal vector of plane surface.
- \(\theta\) :
-
The direction angle between the laser beam and the central axis of the laser collimator.
- \(Ve_{i}\) :
-
The direction error at multiple positions.
- \(M_{lc}\) :
-
The attitude matrix \(M_{lc}\) of the laser collimator.
- \({}_{1}^{2} R\) :
-
The pose relationship from the laser beam coordinate system to the base coordinate system.
- \({}_{4}^{3} R\) :
-
The pose relationship from the turntable coordinate system to the swing table coordinate system.
- \({}_{1}^{4} R\) :
-
The pose relationship from the swing table coordinate system to the equipment coordinate system.
- \(L_{m}\) :
-
The movement range of equipment in Z-axis direction.
- \(Z_{0}\) :
-
The starting position of equipment movement in Z-axis direction
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Acknowledgements
This research was supported by the National Key Development Program of China (Grant No.2016YFB1102500) for supporting this work.
Funding
The National Key Development Program of China, 2016YFB1102500, Dongxiang Hou.
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Hou, D., Wang, X., Song, Q. et al. A quality improvement method for complex component fine manufacturing based on terminal laser beam deflection compensation. J Intell Manuf 35, 331–341 (2024). https://doi.org/10.1007/s10845-022-02048-2
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DOI: https://doi.org/10.1007/s10845-022-02048-2