Laser Diode Test Equipment Simulation Environment

A high-fidelity Python-based simulation environment for laser diode test automation equipment featuring precision motion control, 3D visualization, and comprehensive safety systems.

Features

Core Simulation

• 6-Axis Stage Controller: Precision positioning with X, Y, Z, Rx, Ry, Rz control
• 3-Axis Gantry System: Automated chip loading and positioning
• Probe Stage Controller: Controlled probe press/unpress with force monitoring
• S-Curve Motion Planning: Smooth, jerk-limited trajectory generation
• Micron-Level Precision: 0.1 micron positioning accuracy

Safety & Collision Detection

• Real-Time Collision Detection: Predictive safety interlocks
• Configurable Safety Zones: Restricted area enforcement
• Emergency Stop System: Immediate halt on safety violations
• Force Limiting: Probe force protection and monitoring

User Interface

• 3D Visualization: Real-time stage position display with OpenGL/PyVista
• Multi-Stage Control: Tabbed interface for individual stage control
• Command Editor: JSON-based command creation with validation
• System Monitoring: Live status, warnings, and performance metrics
• Position Trails: Visual tracking of stage movement history

Command System

• JSON Command Interface: Professional Modbus-like command structure
• Command Queue Management: Priority-based execution scheduling
• Batch Command Processing: Automated test sequence execution

Installation

Prerequisites

• Python 3.8 or higher
• Qt5 compatible display system (Linux: X11, Windows: Win32, macOS: Cocoa)

Quick Install

1. Clone the repository:

   git clone <repository-url>
   cd motion_control_simulation

2. Install dependencies:

   pip install -r requirements.txt

3. Run the application:

   python main.py

Optional: 3D Visualization

For the enhanced 3D visualization experience, install PyVista:

pip install pyvista pyvistaqt vtk

If PyVista is not available, the application will automatically fall back to a 2D display mode.

Usage

Basic Operation

1. Start the application:

   python main.py

2. Home all stages:

   • Go to Tools → Home All Stages, or
   • Use the EMERGENCY STOP reset procedure, or
   • Send a HOME command via the command panel

3. Move stages:

   • Use the position controls in the left panel
   • Enter target coordinates and click "Move"
   • Adjust velocity/acceleration as needed

4. Probe operations:

   • Position probe above target
   • Set target Z position and force limit
   • Click "Press Probe" to engage
   • Use "Retract" to withdraw probe

5. Chip handling:

   • Position gantry at chip source
   • Click "Load Chip" to pick up chip
   • Move to destination position
   • Click "Unload Chip" to release

JSON Commands

Move Command

{
  "command_id": "ST0001",
  "command_type": "MOVE",
  "target_stage": "six_axis",
  "parameters": {
    "position": {
      "position": {
        "x": 10500,
        "y": 5200,
        "z": 100,
        "rotation": {
          "rx": 0.0,
          "ry": 0.0,
          "rz": 45.0
        }
      },
      "velocity": 50000,
      "acceleration": 500000
    },
    "execution": {
      "mode": "immediate",
      "priority": 5,
      "timeout": 30.0
    }
  }
}

Probe Press Command

{
  "command_id": "PR0001",
  "command_type": "PRESS_PROBE",
  "target_stage": "probe_stage",
  "parameters": {
    "target_z": -5000,
    "max_force": 800
  },
  "execution": {
    "mode": "queued",
    "priority": 7
  }
}

Home Command

{
  "command_id": "HM0001",
  "command_type": "HOME",
  "target_stage": null,
  "execution": {
    "mode": "immediate"
  }
}

Command Line Options

# Run with custom configuration
python main.py --config my_config.json

# Run in headless mode (for testing)
python main.py --headless

# Enable debug logging
python main.py --debug

# Show version
python main.py --version

Configuration

Stage Parameters

Default motion parameters can be adjusted via the GUI or configuration files:

{
  "stages": {
    "six_axis": {
      "max_velocity": 100000,
      "max_acceleration": 500000,
      "max_jerk": 10000000,
      "position_tolerance": 0.1,
      "velocity_tolerance": 10.0
    }
  }
}

Safety Settings

{
  "safety": {
    "min_clearance": 1000.0,
    "prediction_time": 2.0,
    "auto_emergency_stop": true,
    "warning_distance": 2000.0,
    "force_limit_probe": 1000.0
  }
}

Development

Running Tests

# Run all tests
pytest

# Run with coverage
pytest --cov=core --cov=gui

# Run GUI tests
pytest tests/test_gui.py

Code Style

# Format code
black .

# Lint code
flake8 .

# Type checking
mypy .

Project Structure

motion_control_simulation/
├── core/                   # Core simulation engine
│   ├── data_structures.py  # 3D vectors, positions, states
│   ├── motion_controller.py # Base motion control
│   ├── stage_controllers.py # Specific stage implementations
│   ├── system_controller.py # Main system orchestrator
│   └── collision_detector.py # Safety collision detection
├── gui/                    # User interface
│   ├── main_window.py      # Main application window
│   ├── visualization.py    # 3D visualization widget
│   ├── control_panels.py   # Stage control panels
│   └── main_window.py      # Main application window
├── config/                 # Configuration management
│   ├── command_schema.json # JSON command validation
│   ├── command_schema.py   # Schema validation logic
│   └── settings_manager.py # Persistent settings
├── widgets/                # Reusable GUI widgets
└── tests/                  # Unit and integration tests

System Requirements

Minimum Requirements

• CPU: Intel Core i3 or equivalent
• RAM: 4GB
• GPU: Integrated graphics with OpenGL 3.3 support
• Storage: 100MB free space
• OS: Windows 10, macOS 10.14, or Ubuntu 18.04

Recommended Requirements

• CPU: Intel Core i7 or equivalent
• RAM: 8GB or higher
• GPU: Dedicated graphics with 2GB VRAM
• Storage: 500MB free space (for logs and configurations)

Performance

• Update Frequency: 1kHz for motion control
• GUI Refresh Rate: 20 FPS for visualization
• Position Precision: 0.1 micron resolution
• Memory Usage: <500MB typical operating memory
• Startup Time: <3 seconds on recommended hardware

Troubleshooting

Common Issues

1. PyVista Not Available

   • Application will fall back to 2D mode
   • For full 3D visualization: pip install pyvista pyvistaqt vtk

2. High CPU Usage

   • Reduce GUI update rate in Settings
   • Close unnecessary background applications
   • Ensure adequate cooling

3. Motion Not Responding

   • Check if Emergency Stop is active
   • Verify not in the command queue
   • Restart the application if needed

4. Collision Detection False Positives

   • Adjust safety minimum clearance settings
   • Check stage positioning accuracy
   • Report potential bugs

License

This project is provided for simulation and testing purposes. See LICENSE file for details.

Support

For support and contributions:

• Documentation: See docs/ directory
• Issues: Report via project issue tracker
• Contributions: Follow development guidelines in CONTRIBUTING.md

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Version 1.0 - Simulation Environment for Laser Diode Test Equipment# laser-demo

laser-demo