SYSTEM AND METHOD FOR LASER MARKING A GRAPHIC ON AN OBJECT
20220339736 · 2022-10-27
Assignee
Inventors
Cpc classification
D06P5/2005
TEXTILES; PAPER
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
G05B19/19
PHYSICS
B23K26/0006
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A system and a method for laser marking a graphic on an object. The system includes: a laser system for producing a laser output; element(s) for moving the laser output on a surface of an object; a controller for controlling the laser system and the moving element(s), and for processing control information including a plurality of vectors, where for each vector the controller is configured to set a vector speed and a vector laser power according to a marking intensity value of the corresponding vector group such that at least two vectors within one of the vector groups have with respect to each other different vector speeds and vector laser powers, and a laser output's speed that is set according to the at least two vectors remains different than zero when the laser output travels along two trajectory parts which correspond to the at least two vectors.
Claims
1. A system for laser marking a graphic on an object, the system comprising: a laser system for producing a laser output; moving means for moving the laser output for the latter traveling on a surface of an object; and a controller configured for: processing control information associated with a graphic to be laser marked, said control information comprising or concerning a plurality of vectors, the vectors being separable into two or more vector groups, each group having a corresponding marking intensity value, wherein at least one of said groups has a plurality of vectors; for each vector setting a corresponding vector speed and a corresponding vector laser power; controlling the laser system for setting a power of the laser output according to the vector laser power; controlling the moving means for setting on the surface of the object a trajectory and a speed of the laser output according to each vector and the corresponding vector speed, wherein for each vector the trajectory has a corresponding trajectory part, wherein, for each vector the controller is configured to set the vector speed and the vector laser power according to the marking intensity value of the corresponding vector group such that at least two vectors within one of said vector groups have with respect to each other different vector speeds and different vector laser powers, and such that the laser output's speed that is set according to said at least two vectors remains different than zero when the laser output travels along the two trajectory parts which correspond to said at least two vectors.
2. The system for laser marking a graphic according to claim 1, wherein the controller is further configured to set the trajectory according to a series of the vector groups, said series comprising a particular vector group and a subsequent vector group that follows the particular vector group in said series, and the particular and the subsequent vector groups having different with respect to each other marking intensity values, wherein at least two vectors in the particular vector group and at least one or two vectors in the subsequent vector group form a subseries and have with respect to each other different vector speeds and/or different vector laser powers, and the controller being configured for setting said different vector speeds and/or different vector laser powers such that in said subseries the vector speeds change monotonically, and/or such that in said subseries the vector laser powers change monotonically.
3. The system for laser marking a graphic according to claim 1, wherein the laser output is pulsed and, for controlling the power of the laser output, the laser system is configured for changing a duty cycle of the laser system.
4. The system for laser marking a graphic according to claim 1, wherein the vector speed depends on a length of the trajectory part that corresponds to the vector, an exposition time that corresponds to duration of the laser output irradiating the object's surface while said laser output travelling across said trajectory part, a maximum marking intensity value that the marking intensity value (MI) of the corresponding vector group can acquire, and a correction factor which is related to the laser system, according to the formula:
5. The system for laser marking a graphic according to claim 1, further comprising a computer configured for converting a raster graphic into the control information.
6. The system for laser marking a graphic according to claim 1, wherein the marking intensity value is in a scale that has a maximum marking intensity value and a minimum marking intensity value, said scale being a color grayscale that has FS=255 and FM=0.
7. The system for laser marking a graphic according to claim 1, wherein the controller is configured to set the vector speed to be equal to or smaller than a maximum speed, and wherein when at least one of the vectors the corresponding vector speed is about equal to said maximum speed, the controller is configured to further control the laser system for correcting the power of the laser output.
8. The system for laser marking a graphic according to claim 1, wherein for at least one of the vectors, the corresponding vector speed is larger than a maximum speed, the controller is configured to further control the laser system for correcting the power of the laser output.
9. The system for laser marking a graphic according to claim 1, wherein the laser output is pulsed comprising a number of pulses per vector, said number being 1 or higher, and the laser system which produces the pulsed optical output is configured to change the number of pulses per vector.
10. A method for laser marking a graphic on an object, the method comprising: producing a laser output by means of a laser system; moving the laser output using moving means such that the laser output travels on a surface of an object; processing control information associated with a vector graphic to be laser marked, said control information comprising a plurality of vectors, the vectors being separable into two or more vector groups, each group having a corresponding marking intensity value, wherein at least one of said groups has a plurality of vectors; for each vector setting a corresponding vector speed and a corresponding vector laser power; controlling the laser system for setting a power of the laser output according to the vector laser power; and controlling the moving means for setting, on the surface of the object, a trajectory and a speed of the laser output according to each vector and the corresponding vector speed, wherein for each vector the trajectory has a corresponding trajectory part, wherein, for each vector setting the vector speed and the vector laser power according to the marking intensity value of the corresponding vector group such that at least two vectors within one of said vector groups have with respect to each other different vector speeds and different vector laser powers, and the laser output's speed that is set according to said at least two vectors remains different than zero when the laser output travels along the two trajectory parts which correspond to said at least two vectors.
11. The method for laser marking a graphic on an object according to claim 10, wherein the object comprises a denim fabric.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0037]
[0038]
[0039]
[0040]
[0041]
DETAILED DESCRIPTION
[0042]
[0043] A non-limiting example of the operation of the controller of the system of
TABLE-US-00001 TABLE 1 Vector Marking Grey Scale Group Intensity [0 to 4] 1 1 1 2 3 3 3 2 2
[0044] In the example of Table 1 and
[0045] Each of the vector groups of Table 1 comprise at least one vector, and at least one of the vector groups comprises two or more vectors. Each vector of the vector groups has a corresponding vector distance (Vec. Distance) which is the length of the vector on the surface on which the graphic is to be marked. Preferably all the vectors of the vector groups have the same vector distance. The vector distance is typically measured or expressed in millimetres. In the optional and preferable case that the vector distance is the same for all vectors, the vector distance depends on the resolution of the marking, wherein said resolution is the number of vectors per unit length. Hence, preferably the vector distance is correlated with the resolution via the following relationship:
[0046] Preferably the vector speed v.sub.i for a vector i marked with the system of
[0047] Equation 3 in view of equation 2 may become:
[0048] In equations 3 and 4 the exposition time corresponds to the duration of the laser output irradiating the object's surface while said laser output travels across the trajectory part that corresponds to the vector i on the surface of the object; hence the trajectory part has a length that is equal to the vector distance. Also, in equations 3 and 4 FS is the maximum grayscale colour value that a grayscale level of the vector may acquire in the aforementioned example related to table 1. In the herein described example, the grayscale level for vector i can be considered as expressing the marking intensity MI of the vector group in which vector i belongs. LaserEQ(i) in equations 3 and 4 is a correction factor to adjust the relation between the Laser Emission Time and the emitted laser power. It is often, but not always, required to consider the laser equalization correction factor LaserEQ(i) because often the laser power is not linearly dependent on the laser emission time, in which case for each grey scale value a correction factor is preferably used. A typical CO.sub.2 laser response is showed in
[0049] In the optional and preferred case of working with grayscale graphics using a colour scale that has 255 grey scale levels, i.e. when FS=255 because the grayscale value may be from 0 to 255, then equation 4 becomes:
[0050] Expressing the vector speed as v.sub.i, the vector distance as D which is the length of the trajectory part that corresponds to the vector, the exposition time as t.sub.E that corresponds to duration of the laser output irradiating the object's surface while said laser output travelling across said trajectory part, as well as considering that FS is a maximum marking intensity value that the marking intensity value MI of the corresponding vector group can acquire, and expressing the laser correction factor as LEQi, then from equation 6 it can be derived that in the embodiment of
[0051] Hence, the vector speed v.sub.i may acquire different values depending on the marking intensity MI value of the vector's vector group. In the previous example related to Table 1, the vector speed may vary between a high value, a medium value and a low value, as shown in Table 2:
TABLE-US-00002 TABLE 2 Vector Marking Vector Group Intensity Speed 1 1 High 2 3 Low 3 2 Medium
[0052] Preferably after the speed in each vector is set, then the laser ON and OFF times are calculated for each vector; this calculation is very useful for the embodiment of
[0053] This above means that if the maximum speed is lower than the vector speed that is calculated according to any of equation 1, 3-5, then as the laser beam will move at its maximum speed without being able to go any faster, this will increase the real exposition time in the vector, and to compensate the laser will be off during a period of time, called above LaserOffTime, in order to maintain the original exposition time and keep this way the delivery of energy in that vector.
[0054] When optionally the laser output is pulsed, i.e. comprises laser pulses, then to prevent marking defects the laser off time can be divided (i.e. distributed) between the different laser pulses during the vector.
[0055] Therefore, in the embodiment of
[0056] Once the real laser beam speed is set, e.g. is calculated, then preferably a next step followed by the controller is calculating the acceleration of the laser beam. This calculation may be very useful in the system of
[0057] Usually, the time required for the laser beam to change the speed is called “acceleration time”; in some galvanometer-based systems that may be used in an embodiment of the present invention the acceleration time is constant for most of the speed changes and depends on the defined “Tracking Error” as follows:
Acceleration Time[s]=2*Tracking Error[s], equation 7.
[0058] In equation 7 the acceleration time and the tracking error as measured in seconds (s).
[0059] Preferably to keep the control of the position and speed of the laser beam the controller updates the position of the laser beam in a cycle time/period usually of 10 μs, this period could be higher or lower depending on the performance of the actual controller. Each of these small steps of position may be called “Microvector” or “Acceleration microvector”. A microvector (acceleration microvector) is a vector.
[0060] As the acceleration time is preferably known before reaching a transition point between two vectors, the speed of the laser beam preferably is gradually modified during the transitions by reducing or increasing the speed as may be required.
[0061] The number of microvectors, said vectors also called “acceleration microvectors”, that may be needed to do a change of speed is preferably determined by the following equation:
[0062] Optionally and preferably the microvector duration is constant, and further preferably is 10 μs, in which case equation 8 becomes:
[0063] When having a set of several acceleration microvectors for achieving a change in speed between two consecutive vector groups which belong to a series of vector groups, then preferably an acceleration microvector of the set may belong to a first or current vector group of said two consecutive vector groups, and one or more subsequent acceleration microvectors of the set may be at the beginning of the next or subsequent vector group of the two vector groups. Said set of the several acceleration microvectors for achieving the change in speed between the two consecutive vector groups, is essentially a subseries of vectors that belongs to the series of all the vectors of the corresponding vector group series. The proportion in which the acceleration microvectors of the subseries may be distributed between the two vector groups of the series may vary; according to tests done by the inventors, the best compromise between marking quality and performance is achieved when 50-70% of the subseries's acceleration microvectors belong in one of the first (current) or the second (next or subsequent) vector group, and the other 30-50% of the set's acceleration microvectors belong to the other one of the first or second vector group. In a non-limiting example, good marking quality and performance were achieved when 50% of the subseries' microvectors were in the first vector group, and 50% of the subseries microvectors were in the second group. The way with which said acceleration microvectors may be distributed between two consecutive vector groups may depend on the system moving the laser beam or on the laser system itself.
[0064] Preferably the vector speed of each of the microvectors can be calculated according to the following formula which correlates the “speed (i)” in a vector i, with the “speed (i−1)” of the vector i−1 which immediately precedes vector i:
[0065] In the optional case of having a constant microvector duration and having the number of acceleration microvectors determined according to equation 9, then equation 10 can be rewritten as follows:
[0066] In the example described by Tables 1 and 2 and
Low Speed=0.5×Medium Speed=0.25×High Speed.
[0067] Moreover, in the example described by Tables 1 and 2 and
[0068] Each of the vector groups may comprise a different number of vectors. The length of a vector (microvector) may be different between different vector groups. In the specific example described by Tables 1 and 2 and
TABLE-US-00003 TABLE 3 Vector Marking Vector Vector Vector Group Intensity Speed Microvector Speed Power 1 1 High 1a 1.0x High 100% 1b 1.0x High 100% 1c 0.9x High 90% 1d 0.7x High 70% 1e 0.5x High 50% 1f 0.3x High 30% 2 3 Low 2a 1.0x Low 100% 2b 1.0x Low 100% 2c 1.0x Low 100% 2d 1.0x Low 100% 2e 1.0x Low 100% 2f 1.0x Low 100% 2g 1.0x Low 100% 2h 1.0x Low 100% 3 2 Medium 3a 0.5x Medium 50% 3b 0.7x Medium 70% 3c 0.8x Medium 80% 3d 0.9x Medium 90% 3e 1.0x Medium 100% 3f 1.0x Medium 100% 3g 1.0x Medium 100% 3h 1.0x Medium 100% 3i 1.0x Medium 100%
[0069] In Table 3 each of “High”, “Low” and “Medium” respectively corresponds to the High speed value, the Low speed and the Medium speed value. These values are usually, but not always, measured or expressed in mm/s. As is obvious, in Table 3 “0.5×High” means 0.5 times the High Speed value.
[0070] The vector power in Table 3 is the laser power that is set for each of the microvectors and is expressed as a percentage of a maximum laser power value. Hence, in the example of Table 3 a vector power that is 70% has a value that is 70% of the value of said maximum laser power.
[0071] From Table 3 it can be seen that in vector group 1 there are at least two vectors, e.g. vectors 1e and 1f, for which the controller of the system of
[0072] In Table 3 it can also be observed that vectors 1e and 1f from the particular vector group 1 and vector 2a from the subsequent vector group 2 form a subseries, wherein the particular and the subsequent vector groups 1 and 2 have different with respect to each other marking intensity values, and wherein the vectors 1e, 1f and 2a have with respect to each other different vector speeds, the vector speeds changing, more specifically decreasing, monotonically going from 1e to 2a, because the vector speed in 1e is 0.5×High, the vector speed of 1f is 0.3×High which is smaller than 0.5×High, and the vector speed of 2a is 1×Low=0.25High which is smaller than 0.3×High; this has happened because the controller of the system of
[0073]
[0074] Direction/row B in
[0075]
[0076] Although the controller of the system according to the present invention is based in processing vectors, the image marking process may optionally start using a raster image that contains pixels which indicate the energy levels that need to be applied to the material. The image may be processed, e.g. with a computed that preferably is part of the system and communicates with the controller, using a known in the art algorithm to detect adjacent pixels of similar colour or greyscale values, and group them. Then, an also known in the art fastest path selection algorithm may be applied to find the most time-efficient route. An example of a known bitmap to vectorization algorithm is provided by the AutoTrace program that is available online for converting bitmap to vector graphics. (http://autotrace.sourceforge.net/).
[0077] A preferred embodiment of the method according to the second aspect of the invention is implemented on the basis of the described above function and operation of the preferred embodiment of the system which is according to the first aspect of the invention and can be used for implementing said method. While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. Those skilled in the art will understand that the embodiments disclosed here are non-limitative examples, and other embodiments are possible within the scope or the claims, for example but not limited to, different sequences of the method steps or different combinations of technical features.