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Article history: Laser scanning systems are extensively applied in laser marking, laser printers, laser projection, and
Received 18 December 2007 laser coding. They represent a very mature technique in the marking industry, and the galvanometric
Received in revised form scanning systems are usually adopted in the laser marking system. Although the galvanometric
10 May 2008
scanning system usually increases the marking speed, it is usually accompanied by field distortion. The
Accepted 30 July 2008
Available online 27 September 2008
paper gives a correction method for the field distortion of a laser marking system, which, using the
surface curve fitting function, corrected the control system of the scanning system. The field distortion
Keywords: errors of the laser marking system are corrected by the surface compensation function, which, using the
Field distortion surface curve fitting method, obtained the corrected position of laser spots. The results in this paper
Laser marking system
indicate that field-distortion errors of laser marking systems are effectively corrected by the surface
Compensation
compensation function. Moreover, the compensation method would be widely adopted to increase the
Galvanometric scanning system
accuracy of most two-dimensional machine systems, such as XY table, etc.
Crown Copyright & 2008 Published by Elsevier Ltd. All rights reserved.
1. Introduction beam onto the defined locations via turning scanning mirrors.
Therefore, the mirrors can perform high-speed deflection about an
Laser marking is a rapid, non-contact means of producing axis of rotation of the galvanometric scanning motor. The single
permanent high-resolution images on the surface of most galvos only can deflect a laser beam along a line in an image plane.
engineering materials. The most popular sources are pulsed CO2 The galvanometric scanning system and the position of the laser
laser, Nd:YAG laser and Excimer lasers with average power levels beam must be controlled, both horizontally (X-axis) and vertically
of several tens of watts. The laser beam is scanned over the (Y-axis), to create an image with two axes. XY scanners deflect a
materials using computer-controlled scanning systems, or pro- parallel beam in the X–Y direction. The laser beam enters the
jected through a mask or stencil to generate the images. Laser system through an input aperture. Once inside, the laser beam
scanning methods are widely used in the laser marking processing hits the first mirror on the X scanner and then the second mirror
because the scanning method provides flexibility in character or on the Y scanner deflects it. Accordingly, the laser beam would be
image generation. A few types of laser scanning systems have projected on the defined image field. Scanning systems are of two
been applied in the laser marking system, including the oscillating general types [1]. The first is the pre-objective scanning system, in
mirror, the mutating mirrors, the fiber scan, the rotating polygon which the XY scanners are located in front of an F-theta focusing
and the acousto–optic deflector (AOD), as shown in Fig. 1. Nearly lens, as shown in Fig. 2(a). The other is the post-objective
all laser marking processings are used by oscillating mirrors, scanning system, in which the XY scanners are located behind the
which is usually called the galvanometric scanning system. The focusing lens, as shown in Fig. 2(b).
laser galvanometric scanning method provides an effective Scanning accuracy is an important parameter in the scanning
solution in many image display applications, including medical system, but it is influenced by the errors that cause image
imaging, laser display, laser marking and materials processing. distortion in the scanning system. Xie et al. [2] reported a
Galvanometric scanners combine a mirror with a servo- correction of image distortion for a laser galvanometric scanning
actuator limited-rotation motor, which is the main component system and utilized the correction algorithm to reduce the
in the galvanometric scanning system. They control the laser distortion error of scanning images. The correction is made
by predicting the distortion error of the scanning system using
an F-theta lens to correct the focused image. Although it could
effectively increase the precision of the focusing image, it could
Corresponding author. Tel.: +886 4 7232105x7283; fax: +886 4 7211149. not correct all errors. An error algorithm in machine systems
E-mail addresses: chenmf@cc.ncue.edu.tw (M.-F. Chen), fails to predict various errors because the errors are irregular.
yb2851@gmail.com (Y.-P. Chen), d94631003@mail.ncue.edu.tw (W.-T. Hsiao). Hence, the compensation methods could correct all the errors of
0143-8166/$ - see front matter Crown Copyright & 2008 Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.optlaseng.2008.07.017
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φ
Rotating polygon
ω
α
Rotation
ω
Mirror
Input laser beam Input laser beam Input laser beam
Mirror
AOD
Bragg angle
Fiber Switch
Input laser beam
Input laser beam First order
Zero order
focal lens
Laser beam
Scan Mirror
Laser beam
θ Scan Mirror
focal lens
f
Fig. 2. Types of scanning systems [3]. (a) Pre-objective scanning and (b) post-objective scanning.
the machine system using an error function from the original distortion error is usually accompanied in the scanning system.
errors of the workpiece that were manufactured by the machine Hence, although the scanning system was supposed to draw a
system. Chen et al. [3] have provided a compensation method of square, the actual drawing image would not be a square, it may
field distortion in the CO2 laser drilling system and utilized the appear as a distortion image.
compensation function to reduce the distortion errors and The distortion error of the laser marking system is different
position errors of laser drilling systems. The compensation from the common distortion aberration. The common distortion
function is obtained by the original errors of the scanning system aberration, which causes the projection image to be unlike the
using the Lagrange interpolation method. Although Lagrange objects, is generated by the aberration of optical elements.
interpolation can effectively reduce the errors of the scanning Actually, the image of the laser marking system is generated by
system, the non-continuous result of the scanning image would the scanning points of the control system. Hence, the field
be accompanied in the marking pictures. distortion of the laser marking system is generated by the laser
The distortion of the laser marking system is a two-dimen- beam drift error and optical path error. These various sources of
sional error in the focusing plane, which could be fitted by a errors that influence the scanning system will be discussed.
surface and a two-degree polynomial. Many mathematical
algorithms can fit a surface, including the Cubic Splines, the
Bezier surface, the B-Spline surface, and others [4]. The paper
gives a common algorithm that is a computed surface function by 2.1. Laser beam drift errors
nine points, and corrected the distortion error of the scanning
image using the surface error function. These various errors usually occur as laser beam drift errors in
the laser scanning system, including the mechanical misalign-
ment, the thermal effect, and the assembly errors [2]. Several
2. Error analysis of the galvanometric scanning system mechanical misalignments are produced by fixing the scanning
head, which results in the laser beam drift. Thermal effect will
The galvanometric scanning system is widely used in laser also be the source of the beam drift errors in the laser marking
marking systems because the scanning system provides high system. Moreover, the position transducer of the scanning system
marking speed and fixable processing. However, the field- is sensitive to the change in temperature.
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2.2. Optical path errors affect the results of the projected image, it was associated with a
defect aberration and an unacceptable image in the visual system.
The distortion error does not result in a blurred projection Distortion of the order of 2–3% is typically an acceptable visual
image. In the absence of any other aberration, distortion is system.
manifest in a misshaping of the image as a whole, even though Most laser galvanometric scanning systems for laser drilling
each point is sharply focused. Fig. 3 shows a scanning system with machines use a multi-element F-theta lens to amend the
F-theta lenses, and it indicates the origin of distortion. The laser projected image plane and the scanning velocity. In such a case,
beam incident at an angle on the F-theta lens, passes through it, the distortion represents a great error in the scanning system,
such that a reasonable difference arises between the paraxial because the multi-element lens system greatly increases distor-
angle of refraction and the real ray angle of refraction. Restated, tion. Therefore, correcting the distortion of the scanning system in
distortion arises because different areas of the lens have different a CO2 laser drilling machine is very important. In a CO2 laser
focal lengths and different magnifications. In this case, this caused drilling machine, the distortion error is a pillow-barrel-shaped
the real image to be pulled inward from the paraxial image thus distortion of the square image field, which is caused by the
causing negative or barrel distortion. The amount of distortion is path of the beam in the scan head and by the objective. The
expressed either as a lateral displacement in units of length units control can compensate for this field distortion, and the method of
or as a percentage of the paraxial image height in an image plane. compensation is presented herein.
It is defined as [5]
y ÿ yp
Distortion ¼ 100% (1) 3. Correction of field distortion
yp
where y is the height of the image plane and yp is the paraxial Field-distortion errors in a scanning system normally consist of
height. systematic errors and random errors in the scanning system.
The extent of distortion may be positive or negative. A few A systematic error is defined as the manufacturing error and the
distortions in the galvanometric scanning system, including assembling error. It is repeated in the mechanical systems.
pillow-shaped, barrel-shaped and pillow-barrel-shaped image, Systematic errors of a mechanical system, which were usually
are because of optical path error, as illustrated in Fig. 4. Although obtained by the theoretical analysis and measurement, can
the scanning system was supposed to draw a square, the actual be reduced using the compensation techniques. Although the
image was not a square. A scanning system suffering positive random error was not a repeated error, it could also be
distortion deforms a square array, as shown in Fig. 4(b). In such a compensated for by predicting errors in the system. Accordingly,
situation, each image point is displaced radially outward from the the error compensation technique is a widely accepted method for
center, and the most distant points move farthest. For negative correcting machine errors, and was effective in precision machine
distortion, each point on the image moves radially inward toward design and manufacture. This work gives a normal surface
the center, as shown in Fig. 4(c). Positive distortion typically compensation function, which is consisted of nine points, to
results in a pillow-shaped image in the image plane; negative amend the field-distortion error of laser marking systems.
distortion results in a barrel shape. Although the distortion did not The field distortion of a laser marking system is a two-
dimensional error function in the focusing plane. Methods such as
interpolation and curve fitting can be used in obtaining the
Image plane two-dimensional error functions. The investigation used the
location surface curve fitting method to obtain the compensation function
and correct the field distortion of the laser marking system.
resulting distortion
chie fray The two-dimensional polynomial function z is a polynomial
paraxial
real chief ray function of two variables, x and y—say, of degree 2 each of in x
and y. That is
Z ¼ f ðx; yÞ ¼ a0 þ a1 x þ a2 y þ a3 xy þ a4 x2
þ a5 y2 þ a6 x2 y þ a7 xy2 þ a8 x2 y2 (2)
F-theta lens The function describes the surface; (x, y and z) is a point on it.
The coefficients of the aforementioned function were obtained by
solving this equation, which could be used to estimate the value
Fig. 3. Illustration of field distortion in the laser scanning system with an F-theta of z (f(x, y)) at various values of x and y. The nine unknown
lens [5]. variables of equation can be solved using a set of equations as
Fig. 4. Illustration of different distortions in an optical system [5]. (a) No distortion, (b) pillow shape, (c) ballew shape and (d) pillow-barrel shape.
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25 25 25
20 20 20
15 15 15
10 10 10
Y-direction (mm)
Y-direction (mm)
Y-direction (mm)
5 5 5
0 0 0
-5 -5 -5
-10 -10 -10
-15 -15 -15
-20 -20 -20
-25 -25 -25
-25 -20 -15 -10 5 0 5 10 15 20 25 -25 -20 -15 -10 5 0 5 10 15 20 25 -25 -20 -15 -10 5 0 5 10 15 20 25
X-direction (mm) X-direction (mm) X-direction (mm)
Fig. 5. Simulate the field-distortion error of the scanning system using MATLAB program. (a) pillow-shape distortion, (b) barrel-shape distortion and (c) pillow-barrel shape
distortion.
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by the surface compensation function of the correction scanning laser marking system, which could project spots onto the
angle of a laser marking system, as discussed below. defined position, could be obtained.
The position of the visible laser spots could be measured using 2. Nine points of the scanning area produced the compensation
a photo-sensor, but not all commodity sensors can measure the function for the laser marking system using the surface curve
CO2 laser. Therefore, the position of the CO2 laser spots is typically fitting method, as shown in Eqs. (3)–(17).
measured from the rectangular array holes of a workpiece, which 3. The compensation function of the laser marking system is
are drilled by the laser scanning system. The acrylic plate and integrated into the control system. The correct scanning angles
paper were selected as the compensation specimen, because of of the galvanometric scanning system correct the scanning
their better adsorption in the CO2 laser. Although the positioning angle and eliminate the field distortion in the image plane.
accuracy of the galvanometric scanning system is usually 4. A picture on the graph paper was marked using the CO2 laser
measured by a CCD image processing system, the CCD image marking system, using the compensation technique to reduce
processing does not construct in all of laser marking systems. distortion errors.
Hence, the positions of laser spots of the laser marking system
cannot be measured using the CCD image processing system. In
The correct scanning angles of laser marking systems were found
order to measure the position of laser spots in the laser marking
and the surface compensation polynomial was obtained using the
system, the investigation uses the graph paper to measure the
surface curve fitting method to reduce field distortion of the scanning
position of laser spots. Although the measuring method, which
image plane. Therefore, the laser galvanometric scanning system
uses graph paper to obtain the position of laser spots, would
could be integrated with the compensation program in a control
decrease the positioning accuracy of the laser scanning system,
system that is based on a personal computer. The investigation
the field distortion of the laser marking system would be
reduced the field distortion of laser marking systems using the
effectively reduced. Therefore, the graph paper would be adopted
compensation method that integrated the correct scanning angle of
in correcting the field distortion of laser marking systems.
the scanner in the control system. According to this technique, the grid
The system parameters had a scanning area of 40 40 mm2. The
pattern on the graph paper was marked using a CO2 laser marking
laser was a CO2 laser, with a wavelength of 10,600 nm and a power of
system with compensating field distortion, as shown in Fig. 7(b).
30 W. The scanning system was a pre-objective system. Grids of
A comparison with Fig. 7(a) indicates that the compensation method
3 3 were established over the scanning field to eliminate field
for field distortion improves the processing quality in a laser marking
distortion and the position error of the galvanometric scanning
machine, and the field distortion can be reduced effectively by the
system. The 9 points over the scanning field produced a surface
compensative methods in the laser galvanometric scanning system.
polynomial, and the polynomial was integrated into the control
In order to verify whether the compensation method can
program to adjust the scanning angle of galvos to project the laser
effectively reduce the field distortion that resulted by a laser
spots on the defined position. Fig. 6 schematically depicts the
galvanometric scanning system, the results of the laser marking are
program for correcting field distortion using a personal computer.
made on the CO2 laser marking machine, as shown in Fig. 8. Fig. 8
The procedure for compensating the field distortion is as follows:
1. The laser marking system project laser spots onto the defined
position on the graph paper, which adjusts the scanning angles
of the scanning system. The corrected scanning angle of the
Start
Nine points of corrected Fig. 7. The square array of holes on the graph paper was marked by the laser
scanning angles are established a marking system. (a)Without compensation and (b) with compensation.
surface polynomial using the
surface curve fitting method.
END
Fig. 6. Flowchart of the distortion compensation using the surface curve fitting Fig. 8. Laser marking with field-distortion errors. (a) Pillow-shape distortion and
method. (b) Barrel-shape distortion.
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