Applied Mechanics and Materials Vols. 427-429 (2013) pp 528-532 Online available since 2013/Sep/27 at www.scientific.net © (2013) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMM.427-429.528
Realization of a Modeling and Simulation System for MID Laser Direct Structuring Equipment Wenjuan Hu1, a, Yong Zhuo*1, b, Xuan Wu1, Guowei Lan1, Xin Zhao1 1
School of Physics and Mechanical & Electrical Engineering, Xiamen University, Xiamen, China a
[email protected],
[email protected].
Keywords: MID, Laser Direct Structuring, Open CASCADE, Component Tree, Simulation
Abstract. The LDS is the most advanced and efficient technology in the MID (molded interconnect devices) electromechanical integrated device manufacturing technology. In this paper, the key technologies about modeling of LDS equipment, kinematic analysis of the machine system and optical system and how to combine them to achieve simulation were introduced, the MID modeling and simulation system for LDS equipment was developed based on Open CASCADE, The method of building the component tree was used to achieve the design of the main of the device. By adding the component model and defining the position and sports relationship, completed the three dimensional modeling of main structure and established the motion model. And combined with the MID cellular antenna model, the simulation of the laser machining process about the product has been completed on this system. The result verifies the validity of the simulation system. Introduction MID is an innovations technology in the field of mechatronics which abandoned the conventional board and integrates the mechanical and electronic functions directly on materials[1]. There are many manufacturing process of MID, the most commoms are two molding, hot embossing and laser direct structuring(LDS)[2,3]. The LDS is the most efficient and advanced one in the MID technology[4]. Therefore, the kinematic analysis of LDS equipment and simulation studies can develop processing efficiency, improve processing quality, which are of great significance. At present, the German's LPKF company has researched some LDS equipment[5], for example MicroLine 3D，Fusion 3D 6000，Fusion 3D 1500 and so on. The Molex develops the 3d antenna by using LDS technology. The LDS always has been studying in China, in 2011, the Tontop company designs Precision 3D and Precision 3DC system for three-dimensional circuit laser processing. FOSUNNY, the company has successfully developed single-head laser machine and put it into production. The laser equipment 3D TREATING produced by the turboray company combines the special optics design with the mechanical sense of vision software. Von-magnetic Technology Ltd of Shenzhen has developed a LDS machine, which is large-format, high speed, automatic loading and unloading, its Product capacity can be equal to the 3 head machine Fusion6000 developed by LPKF. This article launches the research on the method to construct the LDS equipment and the simulation process, specifically describes the process by building the component tree to construct the device structure, and combines with the example to illustrate the achievement of simulation for LDS equipment. Function modules of LDS device modeling and simulation system The system (Fig.1) is developed based on Open CASCADE [6] and MFC, which consists of geometric modeling, data exchange, LDS simulation, path planning, and output NC code. Modules are mainly used in geometric modeling module, data exchange module, and LDS simulation module. The geometric modeling module is used to Boolean operations and basic geometric modeling, like cuboid, cylinder, sphere, round table, cones and rings; by data exchange module, IGES, STEP, BREP, CSFDB format data model can be read and save; the function of LDS All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP, www.ttp.net. (ID: 210.34.6.221-06/11/13,10:20:29)
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simulation module is importing LDS devices and work piece model, defining movement relations, transform operations, getting the coordinates and vectors of working points.
Fig.1 Framework of LDS Modeling and Simulation System The preliminary modeling of the machine structure in the system uses geometric modeling module, the data exchange which is provided by Open CASCADE has been used for reading LDS simplified models and work piece model as STEP format or IGES format, and complete assembly modeling of LDS equipment by coordinate transformation, the process simulation is finally realized. Realizations of the LDS Device Modeling The LDS device structure is dominated by five-axis machine with rotary tables, laser system and galvanometer system [1]. The five-axis machine is composed by the Base and a Z axis altar, y-axis rail controls the table movement along the y direction, x-axis rail combines with y direction, and rotary tables built in the x table, and the optical system mainly is consist of the laser, beacon system, the optical path deflecting system, dynamic focusing lens and f-θ lens. Before the simulation, the machine is modeled according to given parameters, including the machine bed, turntable, fixtures and optical system, which can be instead of some simplified model such as cubes, cylinders, revolutions, etc. in order to strengthen the simulation results, initializing the position of all parts when modeling is completed. Equipment structure is shown as in Fig.2(c). This article uses the method of building component tree to create the LDS model, compared to modeling using geometric shapes provided by OCC and importing the whole assembly model with IGES or STEP format, using this method to build a machine model not only includes the component model information and the positional relationship between components, but also can observe the motion relationship between components. The machine model is primarily determined by the geometry model and kinematic model, the geometry model reflects the entity information of the components, kinematic model determines the movement relationship between the components [7], both models are described in the component tree. Component tree contains components information and a component model, to operate the component tree is equal to operate the components. Steps to create the component tree: Right-click in an empty component tree, it pops a menu item (Fig.2 (a)), add the models by selecting “STEP format” or “IGES format”, right-click in the model can relate motion axis by choosing “relate component”. Initialize the default location is (0, 0, 0). It uses this method to complete the component tree which following shown in Fig.2 (b). After adding the component model and defining their position, the machine model is built as shown in Fig.2 (c).
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Fig.2 Realization of Building the LDS Model Generation of the Simulation Path In the simulation system, the laser machining path generation is the key, the generation of laser machining path is to generate processing points’ position coordinates and normal. The method of getting the processing location is discrete representation, which obtains a series of discrete processing points by discrete according to a specified tolerance, then connects these points to approach the machining path of the circuit in turn [8]. The machine model is built to simulate machining cell phone antenna pattern (Fig.3), circuit on the antenna model is a certain width of pattern, in order to generate the laser machining track, it is needed to generate the fill lines according to the pattern, and plan the path in accordance with the requirements of the actual. After filling and getting the coordinates and normal, the result is shown as in Fig.4.
Fig.3 The Model of Phone Antenna
Fig.4 Generation of Path
After generation, the working points must be stored for the processing simulation. In order to improve the processing efficiency, the processing points are stored as follows: For the odd-numbered lines, they are in accordance with the order from the start point to the finish point for storage, while the even-numbered lines, which are stored in accordance with the order from the end to the beginning, so after processing the odd-numbered lines, then directly process from the point in the even-numbered lines that nearest the end. Realizations of the LDS Simulation The function of the simulation system is to dynamic simulate the rapport between five-axis machine system and galvanometer system in processing, and test and analysis the correctness and rationality of machining path generation and path planning, which lay the foundation for actual processing of the MID laser direct structuring.
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After getting the point coordinates and vector is kinematic analysis [9,10], and then reverses values of the variables about the motion axis. The method of the kinematics modeling analysis is D-H, and the direction of displacement and the rotation of the machine and each of parameters of the galvanometer system can be evaluated. In specific applications, it combines these two parts kinematics, when the working points are in the angle range of the laser processing determined by the rotation angle of the galvanometer, if not, the working axis of the machine will be moved or rotated. Specific LDS simulation process is implemented as follows: STEP 1: Establish LDS device model in the simulation system, in this paper, it builds the component tree to build the device model; STEP 2: Clamp the mid work-piece to the table, data exchange module is used to import work piece model with IGES format, and change its location by calling the BRepBuilderAPI_Transform; STEP 3: Pick the routes that on the MID work piece model, and generate the laser machining path, and plan the path, then store it in a collection; STEP 4: Get the position and the normal vector information of the processed point in the collection, calculate the variables’ value of the axis according to the Kinematic analysis. STEP 5: In order to analog simulation, apply the variables’ value, and in view of the movement modules carry on the three dimensional space transformations by calling the gp_Trsf. STEP 6: Determine whether all circuit lines are finished, if finish then end, or go to the STEP 4. STEP 7: End. The result is shown as in (Fig.5) after simulating the phone antenna pattern.
Fig.5 The Process of LDS Simulation Summary In this paper, it describes the achievement of modeling and simulation of LDS equipment, propose the way to build the component tree to create the machine model, which adds the kinematics models to the component tree and the geometric model, and defines the positional relationship between them, during adding the motion axes into the component tree to defined the movement of the components, the movement relations of the components was determined by observing the components and models. Apply the D-H method in kinematic analysis of models, and combine with phone antenna model to detail the generation of simulation path and the process of simulation, instance shows that set up the component tree to build a device model can be directly defined the motion axis of the component models, it is feasible to realize the Simulation of the laser machining process. The research is early for LDS in the exploratory phases, in the future it will continue to improve simulation system, enhance interface interaction, optimize the simulation process, and add the functions of interfering collision detection and output NC code and so on. Acknowledgment The research presented in this paper is supported by National Natural Science Foundation of China (50975241). Second Author is the corresponding author.
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References [1] Yong Zhuo, Yanjun Wu, Juan Peng: Design and Simulation of 3D Layout for MID Based On Open CASCADE, Advanced Materials Research Vol. 479-481 (2012) p. 1978-1981. [2] Yanjun Wu, Yong Zhuo, Juan Peng: Kinematic Analysis and Simulation of MID Laser Direct Structuring Equipment, Advanced Materials Research Vol. 590 (2012) p. 236-241. [3] Zippmann, V.: 10 years of MID Serial Production, in Proceedings of the 7th International Congress on Molded Interconnect Devices, Research Association Molded Interconnect Devices 3D MID e. V., Furth, 2006, p. 71-73. [4] LPKF MicroLine, Flexible FPC - laser prototyping systems, Printed Circuit Information (2006) p.72. [5] Information on http://www.lpkf.cn/products/mid/index.htm. [6] Information on http://www.opencascade.org. [7] Jianqing Yan: An OCC Based Collision Checking System for CNC [D], Harbin: Harbin Institute of Technology, 2010. [8] Yanjun Wu: Development of MID Laser Direct Structuring Equipment and Simulation System [D], Xiamen: Xiamen University, 2013. [9] Zeshi Chen, Chuju Zhang: The Application of D-H Method in the Kinematics Modeling of Five-axis Coordinated Machine Tools, MACHINE TOOL & HYDRAULICS Vol.35(2007) p.88-90. [10] Qiankun Hu: Study of Post-Processing Technology of 5-Axis CNC Programming Based on CATIA [D], Shenyang: Shenyang Institute of Aeronautical Engineering, 2007.
Mechanical Engineering, Industrial Electronics and Information Technology Applications in Industry 10.4028/www.scientific.net/AMM.427-429
Realization of a Modeling and Simulation System for MID Laser Direct Structuring Equipment 10.4028/www.scientific.net/AMM.427-429.528
