Form tolerance-based measurement points determination with CMM

In an intelligent manufacturing environment, computer aided inspection (CAI) provides a critical role in closing the computer aided design (CAD) to computer aided manufacturing (CAM) loop. A coordinate measuring machine (CMM) is often used as a measurement tool in a mechanical part manufacturing environment. Feature-based measurement (FBM) with CMM plays an important role in the concurrent engineering environment (Fig. 1) (Yau and Menq, 1993). It measures a part and feedbacks the results to the concurrent control center to modify related process attributes. Feature-based computer aided inspection (CAI) systems define various measurement attributes for different features (Jacobohn et al., 1990). Part of the system determines the number of measurement points for a feature. In this research, a computer aided feature-based statistical concept is used to calculate sufficient measurement points for a feature. Circular and cylindrical parts are used to demonstrate the proposed methodology for determining the number of measurement points. The results show that the measurement error is significantly lower with the proposed method in determining the number of measurement points as compared to the method commonly used with a CMM. The proposed methodology is also computerized for on-line applications.     

点阵测头成像视觉坐标测量系统的研究

柔性三维坐标测量在工业现场测量有较多应用.分析多目标点透视成像原理的基础上,提出了点阵测头成像视觉坐标测量的概念,给出系统完整的三种数学模型及求解方法.设计了一种实用测头,基于单台面阵CCD摄像机实现由三种类型测头组成的视觉测量样机.在距离摄像机1 000 mm,样机进行实际测量,并与三坐标测量机的检测结果进行比对.测试结果表明在摄像机成像面平行的两个方向的测量精度高于摄像机轴向测量精度.     

三坐标测量机无碰撞检测路径的生成

针对三坐标测量机检测路径的优化与安全问题,提出一种无碰撞检测路径的生成方法.先对测量点按其参数加权和大小规划检测顺序形成初始路径,再通过对测头扫描体表面与零件表面求截面交线进行碰撞检测,结合轴向包围盒过滤提高碰撞检测的效率;对于碰撞的路径段,先对可能存在的外圆特征进行碰撞规避,再对其他碰撞采用启发式规则进行避障移动规划,结合设计的一个扩展包围盒进行避障点设定.最后通过实验验证了文中方法的可行性.实验结果表明,该方法可以在较短时间内生成有效的较优路径,同时能很好地避免碰撞.     

三坐标测量机一般表面上的自适应采样规划

针对CAD模型已知的三坐标测量机一般表面(连续或非连续的基本特征表面)上的常用采样策略中存在的问题,提出一种自适应采样方法,并对测量边和面的情况分别给出了具体的采样算法.通过对选取的表面进行分析,采取步长自适应再分迭代自动规划出相应数目的采样点分布;并使采样点达到均匀分布且避开非连续区域.实验结果表明,该方法对于各种复杂情况的一般表面都有比较好的适应性,弥补了随机采样难以均匀化和基于数字序列采样对表面要求完整连续的不足.     

Generation of reciprocating tool motion in 5-axis flank milling based on particle swarm optimization

This paper proposes a novel method for generation of optimized tool path in 5-axis flank milling of ruled surfaces based on Particle Swarm Optimization (PSO). The 3D geometric problem, tool path generation, is transformed into a mathematical programming task with the machined surface error as the objective function in the optimization. This approach overcomes the limitation of greedy planning methods employed by most previous studies. By allowing the cutter to move backforward, reciprocating tool path produces smaller machining error compared with the traditional one consisting of only forward cutter movement. A cutting experiment is conducted with different tool paths and the CMM measurement verifies the effectiveness of the proposed method.     

Adaptive tilting angles to achieve high‐precision scanning of a dual probes AFM

Atomic force microscopy (AFM) is a powerful measurement tool, widely used in microfabricated structure inspection. However, since it is typical that the fixed tilting angle of a probe is employed in traditional AFM, the corner and sidewall image of the scanned sample would be distorted. To overcome the problem, a so‐called adaptive tilting angle algorithm (ATAA) applied to a self‐designed dual‐probe AFM system is presented to achieve on‐line sidewall estimation during scanning of general samples. Through the use of the proposed ATAA, the tilting angles of dual probes for each scan line can be self‐adjusted to the optimal ones. Overall, a probe tilt mechanism is designed, which allows the AFM system to change the tilting angles of the probes during the scanning process such that the dual‐probe structure AFM can acquire a complete high precision image with just a single scan. The experimental results show the performance of sidewall measurement and the high‐precision image obtained by the proposed method.     

基于ARM的摆式列车倾摆控制检测系统研制

根据摆式列车的基本工作原理,设计制作了基于双CPU的嵌入式线路信息检测系统。系统采用 AMTEL 公司的 AT89S51和 SAMSUNG 公司的 S3C44BOX 两款微处理器分别作为数据采集计算机和倾摆控制主控计算机,通过双端口存储器进行数据通信。在硬件设计的基础上,完成了基于μC/OS-Ⅱ实时操作系统的检测系统软件设计。     

Investigation of point-to-point performance test of touch trigger probes on coordinate-measuring machines

A major factor contributing to the total measuring error of coordinate measuring machines (CMMs) is the performance of the probing sub-system. Probing test methods are typically used to detect errors due to the probing sub-system. The probe performance evaluation method specified in the ANSI B89 standard is investigated in this paper. The sampling plan associated in the probe performance evaluation was tested by using experimental probing data from a CMM. Research findings indicate that the performance of touch trigger probes is overestimated due to a systematic bias in the vertical direction of the best-fit reference ball center in the probe performance test. A two-latitude sampling plan synthesis method based on a pretravel model for touch trigger probes is proposed in this paper. The proposed method can be used to accurately identify the reference ball center in the performance test of touch trigger probes.     

Tool path planning for 5-axis flank milling of ruled surfaces considering CNC linear interpolation

This paper investigates tool path planning for 5-axis flank milling of ruled surfaces in consideration of CNC linear interpolation. Simulation analyses for machining error show insights into the tool motion that generates a precision machined surface. Contradicting to previous thoughts, the resultant tool path does not necessarily produce minimal machining error when the cutter contacts the rulings of a developable surface. This effect becomes more significant as the distance between two cutter locations is increased. An optimizing approach that adjusts the tool position locally may not produce minimal error as far as the entire surface is concerned. The optimal tool path computed by a global search scheme based on dynamic programming supports this argument. A flank milling experiment and CMM measurement further validate the findings of this work.     

基于准循环低密度奇偶校验码的压缩感知测量矩阵

针对随机测量矩阵元素随机产生、不易于硬件实现的缺点,利用有限域上准循环低密度奇偶校验(QC-LDPC)码奇偶校验矩阵的构造方法,设计了一种确定性的结构化稀疏测量矩阵。由于QC-LDPC码的信道编解码性能较好,故以此为基础构造压缩感知(CS)测量矩阵预计有较好的性能。分别用一维和二维信号的CS重建实验验证新矩阵的性能,结果表明,与常用的测量矩阵相比,在相同的重建算法和压缩比条件下,新矩阵对应的重建误差较低,在峰值信噪比(PSNR)的评价指标上有所提高(0.5~1dB)。特别地,所提的确定性测量矩阵在结构上具有对称特性和准循环特性,如将其应用于硬件实现,可降低物理内存的需求量与硬件实现的复杂度。     

大型定子叶片铸件的数字化测量及误差评定

随着航空、航天、船舶、汽车和模具工业的飞速发展,复杂曲面的数字 化测量与误差评定技术对曲面加工精度起着越来越重要的作用。利用激光跟踪测量设备对大 型定子叶片铸件进行了数字化测量,对测量点云进行了去噪、精简等数据处理,并将测量点 云与理论模型进行了基准匹配,计算出了定子叶片铸件各部位的误差分布,实现了对大型定 子叶片铸件的误差评定;测量及误差分析结果可以用于优化叶片在后续加工中的装夹姿态, 使叶片各部位的加工余量趋于均匀,有效提高产品制造精度和加工效率。     

Optimize tool paths of flank milling with generic cutters based on approximation using the tool envelope surface

This paper presents a global optimization method to generate a tool path for flank milling free-form surfaces with a generic cutter based on approximation using the tool envelope surface. It is an extension of our previous work [Gong Hu, Cao Li-Xin, Liu Jian. Improved positioning of cylindrical cutter for flank milling ruled surfaces. Computer Aided Design 2005; 37:1205–13]. First, given initial tool path or tool axis trajectory surface, the grazing points of the tool envelope surface can be calculated. Second, the errors between the tool envelope surface and the designed surface along the normal direction of the tool envelope surface are calculated. Based on this new definition of error, an optimization model is established to get the global optimized tool axis trajectory surface. In order to simplify the calculation, two variants of this method based on the least square criterion are proposed to solve this model. Since this method is really based on the tool envelope surface, it can reduce the initial machining errors effectively. The proposed method can be used not only for cylindrical cutters and conical cutters, but also for generic cutters with a surface of revolution. In addition to ruled surfaces, it also can be used for machining non-ruled surfaces. Finally, several examples are given to prove its effectiveness and accuracy. The generated tool paths and calculated grazing points for test are available in supplementary files for the readers’ convenience in verifying this work in different CAD/CAM systems.     

测量叶尖间缝变化光纤传感器的研究

根据叶尖间隙测量的要求,设计了一种新型的光纤传感器。它采用了单光纤传光、多组光纤束接收散射光的结构。发射光纤位于中心,周围均布多组接收光纤,通过各组接收光纤光强的比值运算,消除了叶尖表面反射率变化对测量结果的影响,也可减小叶尖表面与传感器端面夹角给测量结果带来的影响。在转速同步传感器的配合下,该传感器可以实时测量所有叶片的叶尖间隙。当叶片转速在0~12000 r/min之间变化时,叶尖间隙的测量范围为0~3mm,测量精度为25μm。     

High-resolution ISAR imaging of fast rotating targets based on pattern-coupled Bayesian strategy for multiple measurement vectors

Very high resolution inverse synthetic aperture radar (ISAR) imaging of fast rotating targets is a complicated task. There may be insufficient pulses or may introduce migration through range cells (MTRC) during the coherent processing interval (CPI) when we use the conventional range Doppler (RD) ISAR technique. With compressed sensing (CS) technique, we can achieve the high-resolution ISAR imaging of a target with limited number of pulses. Sparse representation based method can achieve the super resolution ISAR imaging of a target with a short CPI, during which the target rotates only a small angle and the range migration of the scatterers is small. However, traditional CS-based ISAR imaging method generally faced with the problem of basis mismatch, which may degrade the ISAR image. To achieve the high resolution ISAR imaging of fast rotating targets, this paper proposed a pattern-coupled sparse Bayesian learning method for multiple measurement vectors, i.e. the PC-MSBL algorithm. A multi-channel pattern-coupled hierarchical Gaussian prior is proposed to model the pattern dependencies among neighboring range cells and correct the MTRC problem. The expectation-maximization (EM) algorithm is used to infer the maximum a posterior (MAP) estimate of the hyperparameters. Simulation results validate the effectiveness and superiority of the proposed algorithm.     

基于四点偏置法的非可展直纹面侧铣刀位计算

针对非可展直纹面五轴侧铣加工的问题,分析了非可展直纹面几何特点,根据等距 映射下的极差不变性,提出了一种计算非可展直纹面叶片五轴侧铣刀位数据的新方法。以刀具包 络面与设计曲面之间的整体误差为优化目标,建立了圆柱铣刀侧铣非可展直纹面的刀位计算方 法,运用四点偏置法确定初始刀位,采用最小二乘法对初始刀位进行优化,建立刀轴矢量偏转模 型进一步修正刀位以减小过切误差。通过实例计算分析,表明该方法可以在一定程度上减小加工 误差。     

医学三维体数据中的几何测量方法研究

在应用医学图像诊断病情以及放射治疗计划制定中,器官及病变组织的几何测量具有重要的作用。文中基于医学三维体数据研究了空间中任意两点间的距离测量,基于面绘制的三角面片研究了组织器官表面积测量,基于体绘制研究了组织器官的体积测量,在实验中取得了较高的测量精度。     

基于闭环理论的自由曲面测量与实时重构

寻求更优的测量方法和更精确的重构模式一直是逆向工程中的研究重点。基此,对具有自由曲面特征的产品逆向,提出一种自适应测量、实时重构和在线评价的方法。依据几何特性,测量实物外形并用高次Bézier曲线拟合,微分推演探测点及矢量,指导三坐标测量机CMM（Coordinate Measuring Machining）自适应探测完整实物点云;借助非均匀B-spline架构曲面模型,基于扫描网格和实物特征从以上重构的曲面上抽取关键检测点,在线引导CMM确定上述检测点在实物上的准确位置并评价已构曲面误差,若误差高于阀值就将检测点加入更新曲面,逐步提高直至满足几何精度,集成测→构→评→添的全闭环逆向过程,建立精确的实物数字化模型。实例验证表明,该方法可利用曲面的几何特性,让测点分布随曲面曲率变化而呈疏密变化,以获得高质量的原始数据点云,实时模型重构、在线评价并及时添加检测点修正模型,可完整表述曲面的几何信息,可使重构模型精度达微米级。     

An adaptive trajectory planning algorithm for robotic belt grinding of blade leading and trailing edges based on material removal profile model

Robotic belt grinding of the leading and trailing edges of complex blades is considered to be a challenging task, since the microscopic material removal mechanism is complicated due to the flexible contact state accompanied with greatly varying curvature that finally affects the machined profile accuracy. The resulting poor accuracy of blade edges, to a great extent, is attributed to the trajectory planning method which less considers the dynamics. In this paper, an iso-scallop height algorithm based on the material removal profile (MRP) model is developed to plan the tool paths by taking into consideration the elastic deformation at contact wheel-workpiece interface. An improved constant chord-height error method considering the influence of elastic deformation is then proposed to adaptively plan the grinding points according to the curvature change characteristics of the free-form surface. Based on these two steps, a MRP model based adaptive trajectory planning algorithm is constructed to enhance the profile accuracy facing the robotic belt grinding operation. Simulation and experimental results demonstrate the effectiveness of the proposed trajectory planning algorithm for the robotic belt grinding of blades from the perspectives of surface roughness, profile accuracy and processing efficiency. Particularly this technology serves to solve the problem of over-cutting at the blade leading and trailing edges.     

燃气轮机叶片360°轮廓高精度测量

为了寻找一种既能满足叶片测量精度要求,又能解决叶片高精度测量成本高、测量效率低的测量方法,通过搭建基于相位测量的三维轮廓测量系统,对叶片进行360°测量,由于采集的点云数据需要进行数据融合,设计了一种基于相位测量轮廓方法的多角度点云数据融合机械装置,提出了基于参考平面数据旋转的新算法,最终实现了旋转多角度叶片三维轮廓点云数据高精度的自动融合,得到了完整清晰的叶片三维表面轮廓。同时对叶片局部大曲率部位进行测量,为局部二次因素的详细实验测量提供了有利条件。实验结果证明相位测量轮廓术应用于叶片三维轮廓测量非常具有实际价值。     

CCD离散性对面积测量的影响

分析了电荷耦合器件(CCD)在空间和彩色(或灰度)的离散特性对面积测量的影响。通过统计特定区域的边界点和分析图像分割的效果,提出了一种评价CCD相关误差的方法。举例说明了图像分割方法对面积测量的影响很大,为此,讨论了正确使用CCD和提高面积测量精度的相应措施。