基于轨迹包络的三坐标测量空间曲面求交算法的研究

本文提出了基于轨迹包络的三坐标测量空间曲面求交算法,并分别讨论了同向表面与异向表面的求交过程,在三坐标测量中,该方法可直接利用采样数据进行求交计算,具有过程简单、速度快等特点,是一种简便易行的空间曲面求文算法。     

Measuring external profiles of porous objects using CMM

Coordinate measuring machine (CMM) has been extensively used in surface measurement and inspection. CMM produces more accurate and reliable results compared with non-contact measurement devices, since CMM measures target surfaces in a tactile way and is not affected by surface reflection quality. However, when there is porosity on the outside surfaces, CMM measurement will have errors because part of the probing stylus will come into the porosity spaces. This paper presents a method of using CMM to measure external profiles of objects with external porosity spaces. The center of a CMM probing stylus will be compensated to avoid porosity spaces and located above external surface areas along surface normal directions. Such a probing strategy can be implemented in both computer-aided design (CAD)-guided mode and non-CAD-guided mode. When the CAD model is available, the probing styli are guided to approach the surface along its normal directions successively to identify and avoid porosity spaces. When the CAD model is unavailable, surface normal directions will be estimated first and then adjusted. The presented method is able to avoid porosity spaces in CMM measurement regardless of the availability of CAD models.     

未知自由曲面三坐标测量新方法

三坐标测量机(CMM)通常难于实现对未知自由曲面的自动测量,首先需要人工进行测量路径规划,手动控制CMM测量,这种方法不但耗时且测量精度不高。本文提出了一种实时在线灰色预测模型用于控制三坐标测量机的测量。该方法分两个步骤进行:初始化数据测量和实时在线灰色预测自动测量。初始化数据测量主要完成预测用原始数据系列的定义,实时在线灰色预测自动测量则根据原始数据系列预测后续点来控制CMM进行测量。采用这种方法免去了对整个曲面进行测量路径规划,可快速准确地测量自由曲面上的数据而且明显减少测量时间。     

Surface probing simulator for the evaluation of CMM probe radius correction software

Scanning coordinate metrology is largely based on recording the position of a spherical tip which is maintained in contact with the surface to be measured. The coordinate measuring machine (CMM) software converts these tip coordinates into coordinates of points on the measured surface, a process called probe radius correction. In order to investigate the probe radius correction accuracy of specific CMM software in scanning measurements, a surface probing simulator is developed. It calculates the coordinates of probe tip center points (virtual indicated measured points) as raw measurement data by numerically probing a known virtual surface. An iterative solution based on geometric criteria is used to achieve the necessary tangential contact conditions. Various sculptured surface profiles, probe radii, and scanning increments can then be simulated. These raw data are then fed to the CMM software where the probe radius correction is performed. The CMM results are then compared with the known surface to evaluate the probe radius correction accuracy of the CMM built-in algorithm. The simulator allows a rapid CMM software capability check for a variety of situations and may pinpoint shortfalls that may be avoided through alternative measurement procedures. It may also be used to motivate the development of new probe radius correction techniques and assist in their evaluation. Tests were conducted on a Zeiss and a Mitutoyo CMM to demonstrate the usefulness of the simulator.     

A study on the five-axis end milling for sculptured surfaces

The direction vector of milling cutter for CL-data of five-axis milling is obtained by the fact that the bottom part of the milling cutter rides on free-form surfaces using the z-map method. Since the direction vector is known, CL-data can be transformed to the NC-code with regard to the geometry of the five-axis machine and post-processing. For uniform surfaces, the tool path is created from the prediction of cusp heights. After generating the NC-code, a sculptured surface was machined by five-axis end milling and cusp heights on the machined surface were measured by a three-dimensional CMM with laser scanner. From this machining test, it was found that this machining method is effective.     

Reverse engineering of compound surfaces using boundary detection method

This paper proposes an efficient reverse engineering technique for compound surfaces using a boundary detection method. This approach consists in extracting geometric edge information using a vision system, which can be used in order to drastically reduce geometric errors in the vicinity of compound surface boundaries. Through the image-processing technique and the interpolation process, boundaries are reconstructed by either analytic curves (e. g. circle, ellipse, line) or parametric curves (B-spline curve). In other regions, except boundaries, geometric data are acquired on CMM as points inspected using a touch type probe, and then they are interpolated on several surfaces using a B-spline skinning method. Finally, the boundary edge and the skinned surfaces are combined to reconstruct the final compound surface. Through simulations and experimental works, the effectiveness of the proposed method is confirmed.     

Sculptured surface recognition and localization strategy in the CMM process

This paper presents a sculptured surface recognition and localization strategy for the inspection process using the CMM. First, the database is generated from the CAD data based on the Z-Layer concept. Then, the three-dimensional shape of the object on the CMM table is constructed using a vision guided CMM. Two vision cameras are implemented to guide the CMM to the object, and B-spline interpolation method is applied to generate a surface that passes through the obtained data points. As a following step, the Z-layers of the generated surface are created and the geometric properties are calculated to determine the best matching surface in the database. Rough location and orientation of the object are determined by analyzing the image data, and the minimization algorithm is applied as a next step to obtain more accurate localization results. The experimental results show that the proposed method can be applied effectively for sculptured surface recognition and localization in the inspection processes.     

基于变分贝叶斯平行因子分解的缺失信号的恢复

现有的工程信号处理方法都是基于完整的数据采集,并没有考虑缺失信号的处理。而在工程实际中,由于人为因素和自然界不可抗拒的因素,有时会造成传感器失效,从而造成信号采集的缺失。为了消除信号缺失对工程信号处理的消极影响,提出了一种基于变分贝叶斯平行因子分解的信号恢复方法。首先利用平行因子分析理论将采集的振动信号构造成三维张量,同时结合贝叶斯方法,引入潜在变量和超参数,建立贝叶斯平行因子概率图模型;其次采用变分贝叶斯算法推导出因子矩阵和超参数的后验分布,从而进一步推断出缺失元素的分布预测;最后通过分析该模型的下界,初始化参数的选择,使该算法更好的解决信号缺失问题。利用均方根误差和相对平方根误差对该算法的性能进行评估,仿真和实验结果表明,随着缺失比例的增大,变分贝叶斯平行因子分解算法相较于传统的低秩张量补全算法,误差更小,能够更加有效的恢复缺失的信号,有效地解决了工程信号处理中因传感器失效而引起的信号缺失的问题。     

Practical way to measure large-scale 2D parts using repositioning on coordinate-measuring machines

In many situations it is required to perform an inspection of large flat parts on a coordinate-measuring machine (CMM) when it is impossible to probe all necessary surfaces from one position of the part. Or it is necessary to measure a large part which dimensions exceed the volume of an available CMM. For this purpose one needs to merge the data measured in two different positions of the workpiece into one coordinate system. Though most of geodesic software has out-of-the-box functionality to do that, a lot of popular CMM software lacks it. In this paper a practical approach is described to bring a repositioning functionality into a CMM software. The Calypso metrology software was studied. The proposed inspection method can be used both for the measurements of linear dimensions and location tolerances as common practice in Calypso.     

Automated Surface Roughness Measurement

A non-contact roughness sensor is described that is suited for integration with a computer-controlled coordinate measuring machine (CMM). The sensor employs a fibre optic interferometer, electronic control system and data-processing software. The combination of the sensor and computer controlled CMM allows surface texture assessment to be made during scheduled dimensional inspections of complex curved surface components, such as turbine blades. The sensor system will measure surface roughness parameters, for example Ra, using a method that reflects standard procedures. The lightweight sensor head can be mounted on a touch probe arm and the associated articulated mounting head; this combination gives quasi 5-axis positioning ability to the overall sensor. This is suitable for automated surface finish inspection of compound curved surface blades. The sensor and its control unit are integrated with the CMM controller and its operation can be controlled through standard part-program commands used by the CMM.     

自由曲面测量若干关键问题的研究

结合国内外研究现状 ,对自由曲面测量中曲面CAD模型已知时测点的自适应分布、测量路径优化、自由曲面形状误差评定和 CAD模型未知时的测量规划和测点数据处理等几个关键问题的实现方法进行了分析研究 ,并对测点的自适应分布做了仿真研究 ,证明了其有效性     

Reverse engineering from uni-directional CMM scan data

The design and manufacture of sculptured surfaces using the reverse engineering (RE) approach is popular in industry. RE requires the definition of surfaces, a process that is usually performed using a coordinate measuring machine (CMM). However, the present methods for surface model reproduction require a high density of data points, resulting in increased manufacturing times.This paper proposes a method to reduce the manufacturing times. In this method constrained least-square fitting techniques are employed. The splines are then blended to a surface model by a spline segment matching and subdividing algorithm. A model refinement method is proposed, that uses only a fraction of the data points. Experimental results and future developments are also included.     

基于三坐标测量机的螺旋曲面重建

介绍了一种螺旋曲面的重建方法,详细阐述了设计流程。由三坐标测量机获取螺旋曲面数据,实现了测量数据中噪声点的剔除,利用Delaunay三角化重建了曲面。通过滚刀实例的初步验证,说明方法正确可行。     

基于逆向工程的个性化人工膝关节CAD建模

采用接触式的CMM测量设备对人工膝关节自由曲面进行了数字化测量，用Surfacer反求软件分析了测量数据由点到面的处理方法，重构了人工膝关节的CAD三维模型并经CAM模块处理后由数控加工生成应用于临床的产品。个性化膝关节CAD模型的建立对定制人工关节构成了基本自由曲面数据库，不同患者所使用的不同类型关节只需对模型进行局部改动，满足了个性化假体设计需要并缩短产品的开发周期和开发费用。     

Accurate evaluation of free-form surface profile error based on quasi particle swarm optimization algorithm and surface subdivision

Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline(NURBS) for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system(DCS) and measurement coordinate system(MCS) for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization(QPSO) is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%-22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.     

面齿轮磨削齿面齿形误差修正

以面齿轮齿面的形状误差为研究对象,建立了面齿轮齿面数学方程,通过三坐标测量仪（CMM）对面齿轮齿面进行了误差测量。为提高面齿轮齿面的精度,提高其理论和工程的应用价值,提出了一种基于序列二次规划（SQP）的面齿轮齿面误差评定方法。建立了齿面误差的识别方程,应用序列二次规划算法对机床加工参数进行优化求解,并与最小二乘优化法进行对比,应用修正后的机床调整参数,再次通过三坐标测量仪对修正后的齿面误差进行检测,验证了该方法的可行性。     

Effect of probe size and measurement strategies on assessment of freeform profile deviations using coordinate measuring machine

Freeform profiles and surfaces have wider engineering applications. Designers use B-splines, Non-Uniform Rational B-splines, etc. to represent the freeform profiles in CAD, while the manufacturers employ machines with controllers based on approximating functions or splines that can cause deviations in manufactured parts. Deviations also creep in during the manufacturing operations. Therefore the manufactured freeform profiles have to be verified for conformance to design specification. Different points on the profile are probed using a coordinate measuring machine (CMM) and a substitute profile is established from the CMM data for comparison with design profile. The sample points are distributed according to different strategies. In the present work, two new strategies of distributing the points on the basis of curve length and dominant points are proposed considering the geometrical nature of the profiles. Metrological aspects such as probe contact and margins to be provided at the ends have also been included. The results are discussed in terms of form deviation with reference to substitute profile and positional deviation between design and substitute profiles, and compared with results of the strategies suggested in the literature.     

天线回转曲面计算机辅助测量系统--基于Coord3三坐标测量机的回转曲面测量技术

本文论述了利用三坐标测量机测量天线回转曲面面精度的原理,并在此基础上开发了天线回转曲面计算机辅助测量系统,实现了天线曲面面精度的快速测量和数椐处理、分析.     

A PC-based system integrating CMM and CAD for automated inspection and reverse engineering

A personal computer (PC)-based system integrating a manual CMM and a CAD system has been developed for on-line capture of 3D point data, resulting in the automation of the inspection process. The sequence of steps taken to measure a master component using the CMM is stored in a measurement program in teach mode and replayed for repetitive measurement of a batch of identical components in the replay mode. The measurement program guides the CMM operator regarding the geometric entity to be measured, the number of points to be input and the direction to be followed for taking the points on the CMM. The operator has simply to follow the sequence displayed on the computer screen. The program automatically computes the dimensions and the deviations from the corresponding dimensions of the master component. The 3D measurement data from the CMM are transferred to a CAD system in real time. Programs have been developed to create 3D cubic splines and surfaces from the 3D point data taken on the CMM. The full features of the CAD software can be used to manipulate the 3D point data for CAD applications.