高精度大直径测量的新方法研究与实现

大直径回转体工件的直径在线测量问题是长期困扰人们的一个难题。本文提出了一种大直径工件在线高精度测量的新技术及其实现。此技术的基本测量原理是“标记”法,实现的关键技术是采用外设硬件计数器与８０９８单片机的内部计数器对测量脉冲进行测量。本文比较详细地阐述了这种高精度大直径测量技术的测量原理和脉冲的测量方法。     

新型滚轮法大直径测量研究

本文对滚轮法大直径测量仪的测量原理、测量精度进行分析和实验研究。提出新型滚轮法测量大直径的方法,即在原有滚轮测头上增加测量工件表面径向跳动的测微仪,来实现形状误差测量。使一次测量就可以同时测出工件的周长直径和形状误差,解决传统滚轮法无法测量工件形状误差的问题,同时还提出具体的数据处理方法。增加滚轮法的测量功能,拓宽滚轮法的应用范围。     

高精度差动型激光多普勒大直径测量系统

研制了一种可高精度在线测量大尺寸回转体工件直径及圆度误差的差动型激光多普勒大直径测量系统 ,介绍了系统的测量原理及信号处理技术 ,分析了系统测量精度的影响因素     

一种轻便高效的大直径回转支承滚道直径测量装置

研制一种新的测量大型回转支承滚道直径的检测装置.运用弓高弦长测量方法测量,用光栅精确检测弓高数据,通过显示器对测量结果实现数字输出.该装置可以实现用小装置测量大直径.文中介绍了其工作原理、结构组成等,并对该检测装置进行了误差分析.结果表明,该检测装置具有较高的检测精度.     

大型旋转工件直径在线检测系统及误差分析

激光三角法是一种光电检测技术,可以实现长度、距离以及三维形貌检测,测量系统结构简单、测量速度快、能够进行数据的实时处理。基于激光三角测距技术,提出了一种大型旋转工件直径在线测量方法及系统,给出了测量系统的组成结构,对测量系统中主要误差源进行了分类,重点针对系统误差,进行了影响测量精度的误差定量和定性分析,并进行了仿真分析,为以后研究一种大型旋转工件直径自主在线测量机器人奠定了理论基础。     

大直径测量装置的设计

本装置采用感应同步器和电容传感器测量工件大直径。该装置具有测量精度高、方便可靠等特点,既可以进行静态测量,亦可以进行在线检测。     

一套简便的大直径内孔测量装置

针对较大圆柱内孔直径现场测量中出现的测量难度大、测量精度不高的问题，利用圆的自动对中性，设计了一种适用于在生产车间使用的圆柱内孔直径的测量装置。该测量装置结构简单、成本低、测量效率较高，在实际使用中收到满意效果。     

大直径回转支承滚道直径检测装置

研制了一种新的测量大型回转支承滚道直径的检测装置.通过三点式测量方法,用光栅精确检测数据并通过显示器对测量结果实现数字输出.文中介绍了其工作原理、结构组成,并对该检测装置进行了误差分析,结果表明,该检测装置具有较高的检测精度.     

大直径在线测量仪的设计

根据车削加工的特点,采用两个光栅测量工件加工时的外径变化,最后计算出工件直径。仪器采用单片机系统进行测量、计算、显示。介绍了仪器测控系统的功能模块软件设计,最后进行了误差分析。     

大尺寸直径非接触光电检测系统研究

提出了一种基于激光位移测头的大尺寸直径光电测量系统，可用于直径达φ52200mm的大尺寸工件的非接触测量。文章详细论述了测量系统结构、工作原理及同轴度测量方法，并对影响测量精度的主要误差来源进行了分析，结果表明测量精度达0．02mm。     

采用高精度自动定心机构的大尺寸内径测量

圆心定位精度是非接触式大尺寸内径自动测量系统的重要参数,高精度圆心定位是提高系统测量精度的关键。研制了具有高精度自动定心机构的大尺寸内径测量系统,利用双椎体主轴同步定心方法实现测量系统在被测轴孔内高精度自动定心,并通过调节定心支撑臂长度提高圆心定位精度。利用最小平方中值法剔除粗大误差,再利用最小二乘法拟合测量结果,提高了内径拟合精度。使用设计的大尺寸内径测量系统样机对内径直径582 mm的标准环规进行测量,并在大型工件加工现场进行了验证。实验结果表明,本系统的圆心定位精度可达0.012 8 mm,内径和圆度的测量精度可达0.001 mm,标准环规测量重复性稳定在0.006 mm以内,现场测量重复性稳定在0.007 mm以内,能够正确反映大尺寸轴孔的内径和圆度参数,满足测量要求。     

里程表被动齿轮钻孔夹具的改进设计

针对一些直径较小的里程表被动齿轮轴类零件,传统的机用三爪卡盘夹紧零件并钻孔定位困难,并且无法满足加工精度高、大批量生产需求。设计一套专用钻孔夹具,它以气动为动力源,专用夹具结构夹紧通过工件进行钻孔加工,并且适合大规模批量生产。     

Repetitive Measurement and Compensation to Improve Workpiece Machining Accuracy

Achieving workpiece high accuracy at low cost is one of the greatest challenges in the manufacturing industry. A repetitive error measurement and compensation scheme to improve the workpiece diameter accuracy for machining centres is des-cribed. The scheme entails an on-machine measurement and error compensation technology between machining processes. The workpiece diameters are measured along the workpiece length by using a fine touch sensor. The workpiece diameters in the compensation program are modified for implementation of next pass error correction. The technology is realised on a CNC turning centre. This method works well in hard machining and turned workpieces with large length–diameter ratios where the machining process induced errors are significantly greater than errors from other sources. It demonstrates that the work-piece can obtain maximum possible machining accuracy by this repetitive measurement and compensation technique.     

Development of a laser-guiding-type deep small-sized hole-measurement system: Measurement accuracy

In this study, a system for measuring small-sized holes with a 17–21 mm diameter and 1000 mm length was constructed. The system comprises a laser interferometer to detect hole accuracy, a probe connected to a measurement bar, and an optical apparatus for detecting the probe attitude (position and inclination). The probe was supported by supporting pads. A steel workpiece with 18 -mm diameter and 800 mm length was used for the performance test. During the experiment, errors were found in terms of hole deviation and roundness profile. Further experiments, using new experimental apparatus and analysis, revealed the causes of errors: electrical noise that increased with time, two periodic stylus swings in the longitudinal direction of the hole per rotation of the measurement unit, and the excessive spring force pushing the tip of the stylus, causing a large frictional force with the hole wall, etc. If these errors are corrected, high accuracy in the measurement of hole deviation and roundness can be achieved.     

浅谈感应淬火实际应用

利用感应淬火对轴类和钢板类工件进行局部热处理,使热处理硬度符合规定要求。结果表明：通过选用合适频率的感应设备,调整设备的感应电流和加热时间,并用感应设备对工件进行必要的回火处理,就能使轴类和钢板类工件局部热处理硬度符合要求,同时提高了生产效率,降低了生产成本。     

V形测量轴径的方法研究

大批量生产中,采用V形测量轴径,既方便又可直接测量出被测轴径的实际偏差值.V形测量是加工现场的简便、实用轴径测量的精确方法.     

Precision machining of micro tool electrodes in micro EDM for drilling array micro holes

Micro electro discharge machining (micro EDM) is suitable for machining micro holes on metal alloy materials, and the micro holes can be machined even to several microns by use of wire electro discharge grinding (WEDG) of micro electrodes. However, considering practicability of micro holes <Φ100 μm in batch processing, the controllable accuracy of holes’ diameter, the consistency accuracy of repeated machining and the processing efficiency are required to be systematically improved. On the basis of conventional WEDG method, a tangential feed WEDG (TF-WEDG) method combined with on-line measurement using a charge coupled device (CCD) was proposed for improving on-line machining accuracy of micro electrodes. In TF-WEDG, removal resolution of micro-electrode diameter (the minimum thickness to be removed from micro electrode) is greatly improved by feeding the electrode along the tangential direction of wire-guide arc, and the resolution is further improved by employing negative polarity machining. Taking advantage of the high removal resolution, the precise diameter of micro-electrode can be achieved by the tangential feed of electrode to a certain position after diameter feedback of on-line measurement. Furthermore, a hybrid process was presented by combining the TF-WEDG method and a self-drilled holes method to improve the machining efficiency of micro electrodes. A cyclic alternating process of micro-electrode repeated machining and micro holes’ drilling was implemented for array micro holes with high consistency accuracy. Micro-EDM experiments were carried out for verifying the proposed methods and processes, and the experimental results show that the repeated machining accuracy of micro electrodes was less than 2 μm and the consistency accuracy of array micro holes was ±1.1 μm.     

基于三维激光扫描的移动大尺寸圆柱体工件长度快速检测系统

针对移动大尺寸圆柱体工件两端的表面形貌特征,利用三维激光扫描仪设计了一种快速长度在线检测系统。基于三维激光扫描仪可在短时间内连续高速获取大量测量数据的特点,系统在虚拟环境下构造出自适应测量形状的虚拟测量基准面,采用二维误差分离方法抑制系统误差和运动误差,识别定位工件两端端点并计算其到虚拟测量基准面的位移;最后结合多传感器融合模型获取三维位移场测量结果。另外,测试前用三坐标测量机精密测量过的相似形状圆柱体工件对系统进行了校准修正。为验证系统的精度和可靠性,分别对处于（1 000±25）mm内不同直径的圆柱体工件进行了长度检测。结果显示,系统可在1 s完成直径约为50 mm工件的长度测量,检测分辨力为0.010 mm,检测精度达到0.050 mm。实际运行结果表明,该设计系统具有高自动性和高效性,可满足在线生产中对大尺寸工件控制和检测的要求。     

大直径在线高精度测量不确定度分析

讨论了基于"弓高弦长法"测量原理,由3只精密激光位移传感器组成的大直径非接触在线测量装置的测量不确定度。针对被测大轴的尺寸,选择固定的弦长;基于两标准尺寸的外圆盘进行弦长参数的标定;通过3只传感器的对称布置、相对测量、多次测量求平均值等措施,简化了测量装置的结构、方便了标定和测量过程、提高了直径测量精度。对于直径500 mm~510 mm的大轴,当其圆度误差不超过30μm、3只传感器光线的不平行度误差小于0.5°、上下传感器的不对称小于1 mm、标定和测量时中间传感器光线不对中误差小于1 mm时,直径测量结果的不确定度小于3μm。     

漏磁场法测量油管壁厚的研究

在石油开采中,油管内壁杆状磨损和内外壁大面积腐蚀引起的壁厚减薄缺陷是造成油管失效的主要原因之一,本文提出了一种油管壁厚漏磁场测量方法,结果表明,该方法具有精度和灵敏度高,可在线测量等特点,为表面受油泥或其它非导磁性材料覆盖的旧油管的现场检测提供了新的方法与手段。