Dynamic Data Synchronization Laser Marking Technology

The book covers the core principles, hardware configuration, and software logic of a real-time laser marking system.Through the analysis of key steps in the synchronization of dynamic data, the system helps users to solve problems such as the need to quickly apply codes to products on a production line, or the need to personalize products for customers, thereby boosting the efficiency and accuracy of the marking process.It is suitable for people in manufacturing, electronic components, medical equipment and other fields.

Why do we need to label dynamic data?

Nowadays production lines are demanding higher and higher standards for product labeling, such as one code per item, real-time updates of production dates, and even the ability to adjust the content of labels according to order information.Although the traditional laser marking machine is stable, it has problems with delays and misalignment when faced with the need for frequent changes in the data.At this point, the need for synchronization technology becomes clear.

These are the three core modules of the technology.

Optimizing compatibility of hardware configurations.

Choosing equipment: Don't just look at laser power. The key to dynamic synchronous marking is the combination of the motion control card and the sensors.For example, a high-precision servo motor and closed-loop feedback system can ensure that the conveyor belt and laser galvanometer are synchronized.It is suggested that EtherCAT protocol controllers be given priority, as they can control response speed at the microsecond level.

Real-time processing of software logic.

The biggest fear is a software bottleneck.He recommends using C ++ or Python to develop a middleware to process the data, and to pre-load the variables (such as serial numbers and timestamps) from the database into a cache.There's a little trick here: we use multi-threading to separate the data analysis and the instruction issuance. Even if 100 new instructions come in all at once, the machine won't be thrown into confusion.

Synchronizing the mechanism precisely.

Let's talk about the problem of synchronizing the triggering signal.We tested it and found that, at a conveyor belt speed of 2 m / s, using an optical sensor and software compensation, we could keep the positioning error within ± 0.1 mm.When calibrating, remember to first do an idle test, to observe whether the laser beam shifts position as the speed changes, and then fine-tune the delay parameters.

A guide to avoiding pitfalls in practical application.

Most of the time when a customer tells us that their labels aren't keeping up with their production lines, the problem is in one of these three areas.

1. The frequency of updating the data sources is not enough (it is suggested that an industrial database be used).

2. Insufficient bandwidth (a gigabit network port is more stable than USB).

3. Poor heat dissipation can cause the equipment to reduce its speed. (Try adding a water cooling unit.)

This is a typical example of a scene being brought to life.

Last year, for example, it helped a car parts factory overhaul its production line.They want to print a dynamic two-dimensional barcode on the engine block, with each code associated with more than 20 inspection data items.By using OPC UA to connect the MES system, and combining it with visual positioning compensation, we finally achieved high-speed dynamic marking of 60 pieces per minute, and the defective rate fell from 3 % to 0.5 %, "says Huang.

Finally, a word of warning: don't try to save money by buying a "general-purpose" device.Synchronizing dynamic data requires special hardware and software, so it's best to have the supplier provide a customized solution.If the budget is limited, at least make sure that the control system has 30 % of its capacity reserved for future upgrades.