Compensation of installation errors in a laser vision system and dimensional inspection of automobile chassis

Laser vision inspection systems are becoming popular for automated inspection of manufactured components. The performance of such systems can be enhanced by improving accuracy of the hardware and robustness of the software used in the system. This paper presents a new approach for enhancing the capability of a laser vision system by applying hardware compensation and using efficient analysis software. A 3D geometrical model is developed to study and compensate for possible distortions in installation of gantry robot on which the vision system is mounted. Appropriate compensation is applied to the inspection data obtained from the laser vision system based on the parameters in 3D model. The present laser vision system is used for dimensional inspection of car chassis sub frame and lower arm assembly module. An algorithm based on simplex search techniques is used for analyzing the compensated inspection data. The details of 3D model, parameters used for compensation and the measurement data obtained from the system are presented in this paper. The details of search algorithm used for analyzing the measurement data and the results obtained are also presented in the paper. It is observed from the results that, by applying compensation and using appropriate algorithms for analyzing, the error in evaluation of the inspection data can be significantly minimized, thus reducing the risk of rejecting good parts.     

Analysis of digitizing errors of a laser scanning system

The digitizing errors of a high-speed 3D laser scanning system are analyzed and characterized in this paper. As the laser scanner is an electro-optical device and based on the principle of optical triangulation, the measurement accuracy is affected by the measured part geometry and its position within the scanning window. Commercial laser scanners are often calibrated in the scanning plane to account for variation of the incident angle of the laser beam. The effects of the scan depth and the projected angle, characterizing the surface normal of the measured part external to the scanning plane, on the measurement accuracy are not considered in the standard calibration process and have been identified by experiments in the present work. Experimental results indicate that the random error of the scanned data is close to the nominal value provided by the manufacturer. The systematic error shows a bilinear relationship with the scan depth and the projected angle and has a maximum value of about 160 μm. The developed empirical model correctly predicts the systematic error with a maximum deviation of only 25 μm.     

Form-truing error compensation of diamond grinding wheel in CNC envelope grinding of free-form surface

In computer numerical control (CNC) grinding of free-form surface, an ideal arc profile of trued diamond grinding wheel is generally employed to plan 3D tool paths, whereas its form-truing errors greatly influence the ground form accuracy. A form-truing error compensation approach is proposed by using an approached wheel arc profile to replace the previously designed ideal one. The objective is to directly compensate the trued wheel arc-profile errors. It may avoid the time consumption of traditional approach that compensates the measured coordinate point errors of workpiece to an iterative grinding operation. First, the 3D tool path surface was constructed to plan the 3D tool paths. Second, the CNC arc truing of grinding wheel was conducted to analyze the form-truing error distribution relative to the applied wheel arc profile. Then, the form-truing error compensation was carried out in CNC envelope grinding. Finally, the iterative closest point (ICP) algorithm was used to match the measured coordinate points of workpiece to ideal free-form surface. It is shown that the 3D tool path surface constructed is practicable to plan arbitrary 3D tool paths for the form-truing error compensation. The ICP matching may be used to investigate 3D ground form error distribution. It is confirmed that the form-truing error compensation can directly improve the 3D ground form accuracy. It may decrease the 3D ground form error by about 20% when the 2D form-truing error is reduced by about 58% using the same truing conditions for CNC grinding.     

Rapid and accurate reverse engineering of geometry based on a multi-sensor system

The reduction of the lead time in measurement and reverse engineering, and the increased requirements in terms of accuracy and flexibility, have resulted in a great deal of research effort aimed at developing and implementing multi-sensor systems. This paper describes an effective competitive approach for using a tactile probe to compensate the data from a laser line scanner to perform accurate reverse engineering of geometric features. With the data acquired using laser scanning, intelligent feature recognition and segmentation algorithms can be exploited to extract the global surface information of the object. The tactile probe is used to re-measure the geometric features with a small number of sampling points and the obtained information can be subsequently used to compensate the point data patches which are measured by laser scanning system. Then, the compensated point data can be exploited for accurate reverse engineering of a CAD model. The limitations of each measurement system are compensated by the other. Experimental results on three parts validate the rapidity and accuracy of this multi-sensor data fusion approach.     

三维表面扫描机器人误差建模与补偿方法

对于三维表面扫描机器人系统,整个系统的测量误差主要来源于如下几个环节:机器人的本体定位误差、线结构光传感器的数据采集误差和手眼矩阵带来的误差。对于以上环节的各个部分,可以看成是局部过程。不论各个环节或部分的误差为多大,最后的误差均归结于所得到的测量数据。然而,整个系统的误差模型很难通过解析方法得到。为了提高系统的测量精度,通过微粒群径向基神经网络建立系统的误差模型,网络的输入选择激光条纹图像坐标系中的坐标,输出选择为经过迭代最近点算法配准后的最近点与测量点之间的误差。利用微粒群算法优化初始所得的神经元中心和宽度,在相同网络性能的前提下,压缩了网络的规模。在测量过程中利用所建立的误差网络模型将测量误差得以补偿,通过实际的试验验证该方法提高系统测量精度的有效性。     

Three-point method for measuring the geometric error components of linear and rotary axes based on sequential multilateration

The linear and rotary axes are fundamental parts of multi-axis machine tools. The geometric error components of the axes must be measured for motion error compensation to improve the accuracy of the machine tools. In this paper, a simple method named the three-point method is proposed to measure the geometric error of the linear and rotary axes of the machine tools using a laser tracker. A sequential multilateration method, where uncertainty is verified through simulation, is applied to measure the 3D coordinates. Three non-collinear points fixed on the stage of each axis are selected. The coordinates of these points are simultaneously measured using a laser tracker to obtain their volumetric errors by comparing these coordinates with ideal values. Numerous equations can be established using the geometric error models of each axis. The geometric error components can be obtained by solving these equations. The validity of the proposed method is verified through a series of experiments. The results indicate that the proposed method can measure the geometric error of the axes to compensate for the errors in multi-axis machine tools.     

结构光测量中相位误差的过补偿与欠补偿校正

针对现有结构光测量中采用的相位误差补偿算法存在的相位误差过补偿或欠补偿问题,提出了一种新的相位补偿误差校正算法。推导了环境光下四步相移的相位误差数学模型,解释了相位误差过补偿、欠补偿的产生原因;通过数学推导获得相位误差的解析表达式,提出了相位误差过补偿、欠补偿的校正算法。该方法通过向标定平面投射4步相移图像、16步相移图像与黑白图像获得相位误差系数;然后在8种不同环境光条件下重复这一步骤获得多组系数;最后运用参数拟合法获得相位误差数学模型的具体表达式。实验结果表明:无论在黑暗环境还是光环境下,利用该修正方法进行相位误差补偿后均可使相位精度达到0.002rad,比进行相位误差补偿前提高了8.6倍左右,比查找表(LUT)提高了2.5倍左右。该算法精度高,速度快,能有效解决相位误差过补偿、欠补偿的问题。     

航空相机像旋补偿双向控制中的内环补偿器设计

为解决航空相机摆扫成像过程中存在的像旋问题,采用四通道双向控制系统对像旋进行补偿。在系统中,基于鲁棒内环补偿器结构进行了内环补偿器设计。首先利用H∞混合灵敏度优化方法求解鲁棒内环补偿器中的鲁棒控制器,再结合参考模型确定系统的滤波器,进而得到系统化设计的内环补偿器。保证系统鲁棒稳定性的同时尽可能提高干扰抑制性能,进而在两者间折衷提高双向控制像旋补偿精度。实验结果显示,本方法能够有效抑制等效干扰的影响,提高消旋补偿的精度。动态扫描下位置补偿误差的最大值和均方根分别为(1.81×10~(-3))°、(5.224 74×10~(-4))°,与传统设计相比,补偿误差分别减小了41.99%、41.73%,提高了四通道双向控制系统的像旋补偿精度。     

Error compensation method for a gantry robot and a laser-vision sensor-based chassis module measurement system

This paper describes an error compensation method for a 3D laser measurement system based on a gantry robot used for car chassis sub-frame module dimensional inspection. The method is based on a geometrical model that describes possible distortions in gantry robot installation. Implementation of the error compensation model allows a several-fold decrease in gantry robot positioning error.     

神经网络在激光位移传感器误差补偿中的应用

为降低入射角对激光定位移传感器测量精度的影响,提出一种新型的误差补偿方法：先采用ＢＰ神经网络实现测量误差与法矢章动角和进动补偿方法可有效地提高激光位移传感器的测量精度。在此基础上,提一步提出了自由工面测量误差的补偿方法。