应用于工业扫描枪的照明系统设计

针对工业扫描枪扫描时对被扫描面的照明要求,对扫描枪照明模块进行设计。与传统的商用小型扫描枪比,设计的工业扫描枪可实现更大面积均匀矩形的照明光斑,灵敏度与照明面的锐利度都有所提升。采用两种设计方案:一种方案通过拟合一个自由曲面,使光源经过自由曲面后得到所需光斑;另一种基于传统非成像原理设计的照明光路,使用复眼匀光得到所需光斑;根据市场需求,两种设计方案均可在被扫描面距离扫描枪350 mm处呈350 mm×230 mm的均匀矩形照明面,且照明轴上点的强度大于0.2 W/cm2,全部照明面均匀度大于75%。     

基于等几何分析的自由曲面壳体包容式节点力学分析方法

包容式节点作为一种曲面壳体结构的新型节点,展示出优越的抗疲劳力学性能及承载能力。文中针对包容式节点曲面渐进优化设计过程中有限元网格不易调整等问题,将等几何分析理论引入包容式节点这类自由曲面壳体结构的分析。首先从包容式节点曲面的NURBS曲面模型出发,基于Reissner-Mindlin退化壳理论,建立对应的壳体单元,然后通过等几何分析实现对包容式节点自由曲面模型的力学分析,并将其结果与有限元仿真结果进行对比,验证该方法的有效性和适用范围,从而为相关设计及优化提供依据和参考。     

自由曲面形状信息及其反求

对自由曲面的快速反求系统进行了研究。将矩形光栅投影在被测表面上,利用光栅投影法测量自由曲面上每点高度信息。对测量的三维离散数据进行一种特殊的Hermite插值,通过重叠的矩形作用域迭加形成一个由矩形网格表示的新曲面。采用AutoCAD命令绘制三维自由曲面。     

基于递归分割理论的自由曲面建模技术

为应用递归分割理论增强复杂自由曲面建模能力，通过在递归分割Loop方法中引入节点加权因子，实现了对递归逼近分割曲面形状的有效控制，并可以生成不同的尖锐特征。根据曲面模型各点处的平均曲率，对节点位置进行逐步调整，实现了递归分割曲面模型的光顺处理。论述了通过计算递归分割曲面模型的法向偏置面生成薄壁件表面模型的方法，并给出了所建立的自由曲面模型直接应用于快速原型制造的实例，说明应用该项新技术可以直接建立任意拓扑结构复杂自由曲面模型，为复杂自由曲面的建模提供了新的有效途经。     

自由曲面测量中测点自适应规划方法研究

介绍了几种常见的自由曲面测量测点自适应规划方法,分析了现有未知曲面测量方法的不足,针对未知曲面的测量精度和效率问题,提出了一种未知曲面自适应测量的矩形规划方法,以实现沿两维方向的测点自适应,并通过仿真实验验证了该方法的可行性。     

基于微透镜阵列生成特定矩形光斑的TIR组合透镜设计与仿真

LED功率的不断增大使其逐渐替代传统光源,并广泛用于各种照明光源。在某些室内照明以及道路照明设计中,通常需要借助LED透镜产生矩形光斑从而充分利用光能避免浪费。利用Light Tools软件设计了一种全内反射(total internal reflection,TIR)透镜与特定微型透镜阵列的组合透镜,设置TIR准直透镜透射曲面和全反射曲面为二次曲面,并对其进行准直优化。然后建立单个微型透镜,设置单个矩形微透镜长宽比分别为1∶1、3∶2和4∶3,并将其阵列化。通过改变微型透镜的尺寸以及球面曲率半径进行进一步优化,最后生成与微型透镜长宽比对应的均匀矩形光斑,从而满足不同矩形照明区域的照明需求。     

自由反射曲面的软件设计

通过特定的自由反射曲面,可以使得光源的能量重新分布,在指定的投射区实现预期的照明效果.介绍了自由反射曲面的应用领域前景,提出了实现设计自由反射曲面的思路和具体方法,进而指导应用软件的开发,同时阐述了软件设计的思路.     

基于CAD模型引导测量的自由曲面定位及轮廓度误差评定

提出将粒子群优化算法与拟随机序列法相结合对基于CAD模型引导测量的自由曲面进行高精度检测和轮廓度误差评定的方法。为解决用三坐标测量仪检测自由曲面时存在的设计坐标系与测量坐标系不重合问题,提出用拟粒子群优化算法来实现被测曲面与设计曲面精确定位;针对自由曲面特点,采用轮廓峰谷误差和轮廓均方根误差综合评定自由曲面的形状误差。最后,阐述了用拟粒子群优化算法实现曲面匹配时目标函数值的计算方法,确立了用拟粒子群优化算法优化求解参数向量的具体步骤。对仿真实例和大量实测零件自由曲面轮廓度误差的计算表明:采用本文方法能够实现自由曲面精确定位,其轮廓度误差评定精度比由三坐标测量仪内置软件计算的结果高8%～15%,适用于对高精度自由曲面零件形状误差的评定。     

基于刚架模型的多张B样条曲面变形

针对由多张B-spline曲面拼接构成的曲面形状修改问题,提出了一种多张B-spline曲面变形算法。通过将曲面片控制顶点网格进行“合并”来建立多张B-spline曲面的刚架模型;以刚架节点位移为未知量,建立节点载荷最小和节点位移最小的统一优化目标函数;将曲面片之间的光滑拼接条件抽象为节点相对位置约束,结合点约束、点和法矢约束共同组成约束方程组;采用罚函数法求解得到变形后曲面新的控制顶点。变形实例表明该算法是直观有效的。     

自由曲面超声检测机器人运动学分析

在对自由曲面超声检测机器人进行结构分析的基础上,采用Denavit-Hartenberg方法建立了连杆坐标系下的机器人运动学模型,对其进行了运动学正向、逆向分析求解,并通过实验数据证明了该解方法的正确性。事实证明,通过对该检测机器人进行的运动学分析,可为计算机控制检测探头进行曲面检测提供准确的控制参数,为实现自由曲面连续的仿形超声检测提供可靠的方法和理论依据。     

自由曲面数控加工刀具轨迹曲线的一种生成算法

提出一种自由曲面数控加工轨迹曲线计算方法。根据这一方法,可由自由曲面上一定数量的任意分布型值点来 计算曲面加工时的刀具曲线。算法的基本思想是,型值点影响并决定着其控制区域内的曲面形状,这种影响的大小与到 型值点的距离及权指数相关。分别给出了沿X向进给及Y向进给时刀具轨迹曲线的生成算法。讨论了算法中参数选取 对加工曲面形状及拟合精度的影响。     

模块化等亮度LED路灯设计

针对当前LED路灯照明采用照度均匀的设计方法无法满足道路照明实际需求的情况,通过推导自由母线的偏微分方程,在研究路灯配光特性的基础上,应用SolidWorks软件建立LED路灯的光学模型,将光学模型导入TracePro软件进行仿真,应用DIALux软件模拟实际道路场景和路面的光照情况,完成一款符合国家标准的LED道路照明灯具配光设计。设计灯具的路面亮度总均匀度和路面纵向均匀度分别为0.82和0.77,都高于国家照明标准,既满足亮度均匀性的要求,也满足照度均匀性的要求。并研发了一款全新的模块化灯具结构,实用方便,市场前景广阔。     

Image processing-based accessibility analysis method for determining undercut-free parting direction

In injection molding, demoldability of a part without the use of a side core is possible only if all of its surfaces are fully accessible in the parting direction. A mold surface may be fully accessible from some directions, but may not be accessible from other directions. Therefore, to determine the undercut-free parting direction, an algorithm is developed that evaluates the accessibility of each part surface from a set of directions (called as candidate parting directions) by using image processing techniques. In the proposed methodology, the surface accessibility is determined by comparing the projected area of each surface on the image plane in the presence of other part surfaces to that of the same surface in the absence of other part surfaces. The algorithm can be used to determine the accessibility of planar, ruled, and free-form surfaces without tessellating the part surfaces. The algorithm includes a method that can also successfully classify surfaces that are oriented perpendicular to the parting direction. The surface classification can be used to identify the undercut-free parting direction, recognize the various undercut features, and form the visibility maps. The accuracy of the algorithm depends upon the number of pixels used to represent the part on the computer screen. The method has been successfully implemented, and test results are discussed in this paper.     

FREE-FORM SURFACE MACHINING AND COMPARING FEEDRATE SCHEDULING STRATEGIES

This article presents mathematical models of cutting forces and surface-form errors for machining of free-form surfaces. Besides the predictive models of cutting forces and surface deflections, a newly developed force based feedrate scheduling (FFS) technique is compared with material removal rate (MRR) based feedrate scheduling method that was used in feedrate optimization packages. With the experimental validations in free-form surfaces, it is shown that the mechanic models predict the forces and surface-form errors quite well. Moreover, by modifying the CNC programs with the new FFS technique, cycle times of the free-form parts can be decreased significantly.     

FREE-FORM SURFACE MACHINING AND COMPARING FEEDRATE SCHEDULING STRATEGIES

This article presents mathematical models of cutting forces and surface-form errors for machining of free-form surfaces. Besides the predictive models of cutting forces and surface deflections, a newly developed force based feedrate scheduling (FFS) technique is compared with material removal rate (MRR) based feedrate scheduling method that was used in feedrate optimization packages. With the experimental validations in free-form surfaces, it is shown that the mechanic models predict the forces and surface-form errors quite well. Moreover, by modifying the CNC programs with the new FFS technique, cycle times of the free-form parts can be decreased significantly.     

Buckling analysis of laminated plates using the extended Kantorovich method and a system of first-order differential equations

The extended Kantorovich method using multi-term displacement functions is applied to the buckling problem of laminated plates with various boundary conditions. The out-of-plane displacement of the buckled plate is written as a series of products of functions of parameter x and functions of parameter y. With known functions in parameter x or parameter y, a set of governing equations and a set of boundary conditions are obtained after applying the variational principle to the total potential energy of the system. The higher order differential equations are then transformed into a set of first-order differential equations and solved for the buckling load and mode. Since the governing equations are first-order differential equations, solutions can be obtained analytically with the out-of-plane displacement written in the form of an exponential function. The solutions from the proposed technique are verified with solutions from the literature and FEM solutions. The bucking loads correspond very well to other available solutions in most of the comparisons. The buckling modes also compare very well with the finite element solutions. The proposed solution technique transforms higher-order differential equations to first-order differential equations, and they are analytically solved for out-of-plane displacement in the form of an exponential function. Therefore, the proposed solution technique yields a solution which can be considered as an analytical solution.     

Fast and Flexible Non-Null Testing of Aspheres and Free-Form Surfaces with the Tilted-Wave-Interferometer

The Tilted-Wave-Interferometer (TWI) is a non-null, full-field interferometric measuring technique for aspheric and free-form surfaces with a new degree of flexibility. The interferometer uses a set of tilted wavefronts to locally compensate the deviation of the surface under test from its spherical form. Since it is a non-null technique, there is no need for costly compensation optics. The measurement data acquisition is highly parallelized, leading to a short measurement time in the region of few seconds, by simultaneously achieving a high lateral resolution. The unique combination of these characteristics makes the TWI a perfect candidate for the integration into the process chain of aspheric and free-form surface manufacturing.     

基于三角剖分的曲面变形

介绍一种三维空间中基于散乱数据点三角剖分的自由变形技术。运用Voronoi图和Delaunay三角剖分,将待变形曲面上的点(作用点)用控制顶点线性表示出来,移动控制顶点使作用点发生位移,从而使曲面的形状发生局部的改变。这种方法改进了诸如自由变形(FFD)、直接自由变形(DFFD)和扩展自由变形(EFFD)等传统曲面变形技术在局部变形上的应用。