大型结构件检测的关键技术与实验研究
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摘要
本文在国家“863”计划支持下,基于FARO激光跟踪仪测量系统,研究了大尺度工件测量中曲面造型、测量规划、数据处理以及误差评定等关键技术,为保证大型工装夹具的产品质量奠定了理论基础,论文取得主要研究成果如下:
采用计算几何理论,推导了型值点自动选择算法;基于五次B样条插值型值点构造曲面轮廓线,并通过VB编程快速构建曲面模型,为曲面检测提供测量模型。
基于坐标变换原理推导了测量数据与理论模型的配准算法,为测量数据处理奠定了基础。
采用间接平差理论推导了平面拟合参数算法,进而构建了判定工件平面形位误差模型;通过求解测量点组到理想曲面的距离偏差和判定其矢量方向确定了曲面轮廓度误差评价方法。
以大型工装夹具为对象进行了现场检测,根据检测要求构建检测模型、检测流程规划,在此基础上进行样件测量工作,最后通过数据处理评价大型结构件加工装配误差,并分析了影响测量精度的主要因素以及测量的不确定度。
上述研究成果运用到大型工装夹具加工、组装和检测中,保证了产品的质量,为后续的误差溯源、产品终检、加工和装配工艺的改进提供了依据。
This dissertation is focused upon the development of a complete theoretical package in terms of the surface modeling, measure planning, data processing and error analysis of large-scale structure measurement using a FARO laser tracker system. The following works have been completed:
With the aid of the principle of computational geometry, the algorithm of characteristic points selected has been conducted by controlling the maximum tolerance between the approximate curves of quintic polynomial and all the points, then the contour line was constructed by interpolating the selected points with the quintic B spline, the surface was shaped rapidly through visual basic programming.
Based on the coordinate transform theory, this work develops a digitized point sets registration method, which is used to matching the frame of measurement with the reference frame.
Aiming at the error evaluation on positional tolerance and the profile error, the algorithm of plane fitting was developed according to the indirect adjustment theory, and the profile error for curved surface was estimated through calculating the vector between the measuring points and the nominal model.
Based on the experiment of large scale jigs detection, the process of measuring was developed with the geometric modeling, measuring planning and error analysis . Simultaneity the factors affect the measurement precision was analyzed and the measurement uncertainty was estimated.
These research results have some guiding effects on the measurement of large scale structure and provide theoretical foundation of the follow up error tracing and processing improvement ,therefore the study is of great significance theoretically and practically for large-scale parts agile manufacturing.
采用计算几何理论,推导了型值点自动选择算法;基于五次B样条插值型值点构造曲面轮廓线,并通过VB编程快速构建曲面模型,为曲面检测提供测量模型。
基于坐标变换原理推导了测量数据与理论模型的配准算法,为测量数据处理奠定了基础。
采用间接平差理论推导了平面拟合参数算法,进而构建了判定工件平面形位误差模型;通过求解测量点组到理想曲面的距离偏差和判定其矢量方向确定了曲面轮廓度误差评价方法。
以大型工装夹具为对象进行了现场检测,根据检测要求构建检测模型、检测流程规划,在此基础上进行样件测量工作,最后通过数据处理评价大型结构件加工装配误差,并分析了影响测量精度的主要因素以及测量的不确定度。
上述研究成果运用到大型工装夹具加工、组装和检测中,保证了产品的质量,为后续的误差溯源、产品终检、加工和装配工艺的改进提供了依据。
This dissertation is focused upon the development of a complete theoretical package in terms of the surface modeling, measure planning, data processing and error analysis of large-scale structure measurement using a FARO laser tracker system. The following works have been completed:
With the aid of the principle of computational geometry, the algorithm of characteristic points selected has been conducted by controlling the maximum tolerance between the approximate curves of quintic polynomial and all the points, then the contour line was constructed by interpolating the selected points with the quintic B spline, the surface was shaped rapidly through visual basic programming.
Based on the coordinate transform theory, this work develops a digitized point sets registration method, which is used to matching the frame of measurement with the reference frame.
Aiming at the error evaluation on positional tolerance and the profile error, the algorithm of plane fitting was developed according to the indirect adjustment theory, and the profile error for curved surface was estimated through calculating the vector between the measuring points and the nominal model.
Based on the experiment of large scale jigs detection, the process of measuring was developed with the geometric modeling, measuring planning and error analysis . Simultaneity the factors affect the measurement precision was analyzed and the measurement uncertainty was estimated.
These research results have some guiding effects on the measurement of large scale structure and provide theoretical foundation of the follow up error tracing and processing improvement ,therefore the study is of great significance theoretically and practically for large-scale parts agile manufacturing.
引文
[1]李剑,王文,陈子辰,自由曲面测量若干关键问题的研究[J],机械科学与技术,2001,20(5):764-766
[2]黄桂平,叶声华,经纬仪非接触大尺寸三坐标测量系统的开发及其在航天器检测中的应用[J].上海计量测试,2002,29(3):9-12
[3] W.T. Estler, K.L. Edmundson, G.N. Peggs, D.H. Parker,Large-Scale Metrology - An Update,CIRP Annals - Manufacturing Technology,2002,51(2):587-609
[4]叶晓明,凌模,全站仪原理误差,武汉:武汉大学出版社,2004
[5] CARBONE V,CAROCCI M,SAVIO E,Combination of a vision system and a coordinate measuring machine for the reverse engineering of freeform surfaces[J],International Journal of Advanced Manufacturing Technology,2001,17(4):263-271
[6]张顺德,卢秉恒,丁玉成,光学三维型面分区域测量数据的拼接研究[J],中国激光,2001,28(6):533-536
[7]龙玺,钟约先,李仁举,结构光三维扫描测量的三维拼接技术[J],清华大学学报,2002,42(4):477-480
[8]李晓星,康绍峥,周贤宾.立体视觉与空间编码技术相结合的非接触三维曲面测量系统[J].中国机械工程,2004,15(9):806-809
[9]王平江等,空间自由曲面数控测量系统中的测量路径的优化,组合机床与自动化加工技术,2004,10:30-35
[10] Menq Chiairsiang,Yan Hongtzong,Lai Gwanywan,Automated precision measurement of surface profile in CAD-directed inspection[J],IEEE Transactions on Robotics and Automation,1992,8(2):268～278
[11] Vosniakos G C,Giannakakis T,Reverse-engineering of simple surfaces of unknown shape with touch probes: scanning and compensation issues[C],Professional Engineering Publishing,2003,217 (4):563
[12]王增强,任军学,CMM测量曲面侧头半径补偿与路径规划研究,机床与液压,2006,3:75-77
[13] Hocken R J,Raja J,Babu U,Sampling issues incoordinate metrology,Manufacturing Review,1993,6(4):282-294
[14] Smith K B,Zheng Y E Multi-laser displacement sensor used in accurate digitizing technique,Transactions of the ASME,Journal of Engineering for Industry,1990,16(11):482-490
[15] Woo T C , Liang R,Dimensional measurement of surfaces and their sampling,Computer Aided Design,1993,25(4):233-239
[16] Kim W S,Raman S,On the selection of flatness measurement points in coordinate measuring machine inspection,International Journal of Machine To ls and Manufacture,2000,40:427-443
[17]来新民,黄田,陈关龙等,自由曲面数字化的自适应规划,上海交通大学学报,1999,33(7):837~84
[18] Kam C L,A geometric decomposition method for part programming of CMMS,Autofact Europe Conf.,1993:1315-1324
[19] Pahk H J,Kim Y H,Hong Y S,Development of computer-aided inspection system with CMM for integrated mold manufacturing,Annals of the CIRP,1993,42:557-572
[20] Lee G,Mou J,Shen Y,Sampling strategy design for dimensional measurement of geometric features using coordinate measuring machine,Tools Manufac,1997,37(7):917~934
[21] Loe.k.F., Energy-based smoothing of data, Mathematics and Computers in S imulation,1993, 35(3): 271-278
[22]彭芳瑜,曲面数控加工中的拟合、光顺及干涉问题研究,武汉:华中科技大学,2000
[23]周云飞,周济,基于广义能量法的截面曲线光顺,工程图学学报,2005,2:87-93
[24]李海滨等,转子叶片表面测量数据光顺方法的研究,机械科学与技术,2002,17(3):461-465
[25]马平,数字图像处理和压缩,北京:电子工业出版社,2007
[26] Xiao-Bai Li,Varghese S.Jacob,Adaptive data reduction for large-scale transaction data, European Journal of Operational Reaserch,2008,188:910-924
[27]王伯平,曾建潮,一种自调整的空间面轮廓度误差的评定方法[J],计量学报,2002,23(2):106
[28] J-Y Lai, W-D Ueng, C-Y Yao, Registration and data merging for multiple sets of scan data[J], Advanced Manufacturing Technology,1999,15 (1), 54-61
[29]王林艳,王建华,基于坐标法的复杂曲面轮廓度的误差评定,西安工业学院学报,2006,26(3):228-232
[30] http://www.spatialanalyzer.com/sa_documents.htm,2005-5-20
[31] Wang Y, Gupta S,Hulting F, et a1,Manufactured part modeling(MPM) for characterization of geometric variations of automotive space frame extrusions,Journal of Manufacturing Science & Engineering,Trans of ASME,1998,120(2):523-531
[32] Barcenas C C, Griffin P M,Parametric-based determination of cylindrical variations in geometric tolerancing,Journal of Manufacturing Science& Engineering, Trans. Of ASME,2000,122: 549-55
[33] Jin Tao , Kuang Jiyong ,A 3-D point sets registration method in reverse engineering ,Computer & Industrial Engineering ,2007:270-276
[34]张春富,张军,唐文彦等,一种基于模式搜索的大尺寸测量移站坐标转换方法[J],航空计测技术,2003(6):12-14
[35]丁汉,朱利民,熊振华,复杂曲面快速测量、建模及基于点云的RP和NC加工,机械工程学报,2003,39(11):28-37
[36]李耀东,黄成祥,基于CAD模型的曲面检测方法,四川大学学报,2004,1(36):90-93
[37] Forbes A B,Harris P M,Simulated Instruments and Uncertainty Estimation [R],NPL Report,2000
[38] Savioa E,De Chifre L,An artifact for traceable free-form measurements On coordinate measuring machines[J],Precision Engineering,2002,26(1):58-60
[39] Monte-CarloSiebert,B R L,Waldele F,Kunzmann H,Assessment of uncertainties in dimensional metrology by Monte—Carlo simulation:Proposal of a modular and visual software[J],Annals of the CIRP,2000,49(1):395-398
[40]张曦,陈五一,激光跟踪仪测量曲面的测量不确定度研究[J],计量学报,2006,27(2)
[2]黄桂平,叶声华,经纬仪非接触大尺寸三坐标测量系统的开发及其在航天器检测中的应用[J].上海计量测试,2002,29(3):9-12
[3] W.T. Estler, K.L. Edmundson, G.N. Peggs, D.H. Parker,Large-Scale Metrology - An Update,CIRP Annals - Manufacturing Technology,2002,51(2):587-609
[4]叶晓明,凌模,全站仪原理误差,武汉:武汉大学出版社,2004
[5] CARBONE V,CAROCCI M,SAVIO E,Combination of a vision system and a coordinate measuring machine for the reverse engineering of freeform surfaces[J],International Journal of Advanced Manufacturing Technology,2001,17(4):263-271
[6]张顺德,卢秉恒,丁玉成,光学三维型面分区域测量数据的拼接研究[J],中国激光,2001,28(6):533-536
[7]龙玺,钟约先,李仁举,结构光三维扫描测量的三维拼接技术[J],清华大学学报,2002,42(4):477-480
[8]李晓星,康绍峥,周贤宾.立体视觉与空间编码技术相结合的非接触三维曲面测量系统[J].中国机械工程,2004,15(9):806-809
[9]王平江等,空间自由曲面数控测量系统中的测量路径的优化,组合机床与自动化加工技术,2004,10:30-35
[10] Menq Chiairsiang,Yan Hongtzong,Lai Gwanywan,Automated precision measurement of surface profile in CAD-directed inspection[J],IEEE Transactions on Robotics and Automation,1992,8(2):268～278
[11] Vosniakos G C,Giannakakis T,Reverse-engineering of simple surfaces of unknown shape with touch probes: scanning and compensation issues[C],Professional Engineering Publishing,2003,217 (4):563
[12]王增强,任军学,CMM测量曲面侧头半径补偿与路径规划研究,机床与液压,2006,3:75-77
[13] Hocken R J,Raja J,Babu U,Sampling issues incoordinate metrology,Manufacturing Review,1993,6(4):282-294
[14] Smith K B,Zheng Y E Multi-laser displacement sensor used in accurate digitizing technique,Transactions of the ASME,Journal of Engineering for Industry,1990,16(11):482-490
[15] Woo T C , Liang R,Dimensional measurement of surfaces and their sampling,Computer Aided Design,1993,25(4):233-239
[16] Kim W S,Raman S,On the selection of flatness measurement points in coordinate measuring machine inspection,International Journal of Machine To ls and Manufacture,2000,40:427-443
[17]来新民,黄田,陈关龙等,自由曲面数字化的自适应规划,上海交通大学学报,1999,33(7):837~84
[18] Kam C L,A geometric decomposition method for part programming of CMMS,Autofact Europe Conf.,1993:1315-1324
[19] Pahk H J,Kim Y H,Hong Y S,Development of computer-aided inspection system with CMM for integrated mold manufacturing,Annals of the CIRP,1993,42:557-572
[20] Lee G,Mou J,Shen Y,Sampling strategy design for dimensional measurement of geometric features using coordinate measuring machine,Tools Manufac,1997,37(7):917~934
[21] Loe.k.F., Energy-based smoothing of data, Mathematics and Computers in S imulation,1993, 35(3): 271-278
[22]彭芳瑜,曲面数控加工中的拟合、光顺及干涉问题研究,武汉:华中科技大学,2000
[23]周云飞,周济,基于广义能量法的截面曲线光顺,工程图学学报,2005,2:87-93
[24]李海滨等,转子叶片表面测量数据光顺方法的研究,机械科学与技术,2002,17(3):461-465
[25]马平,数字图像处理和压缩,北京:电子工业出版社,2007
[26] Xiao-Bai Li,Varghese S.Jacob,Adaptive data reduction for large-scale transaction data, European Journal of Operational Reaserch,2008,188:910-924
[27]王伯平,曾建潮,一种自调整的空间面轮廓度误差的评定方法[J],计量学报,2002,23(2):106
[28] J-Y Lai, W-D Ueng, C-Y Yao, Registration and data merging for multiple sets of scan data[J], Advanced Manufacturing Technology,1999,15 (1), 54-61
[29]王林艳,王建华,基于坐标法的复杂曲面轮廓度的误差评定,西安工业学院学报,2006,26(3):228-232
[30] http://www.spatialanalyzer.com/sa_documents.htm,2005-5-20
[31] Wang Y, Gupta S,Hulting F, et a1,Manufactured part modeling(MPM) for characterization of geometric variations of automotive space frame extrusions,Journal of Manufacturing Science & Engineering,Trans of ASME,1998,120(2):523-531
[32] Barcenas C C, Griffin P M,Parametric-based determination of cylindrical variations in geometric tolerancing,Journal of Manufacturing Science& Engineering, Trans. Of ASME,2000,122: 549-55
[33] Jin Tao , Kuang Jiyong ,A 3-D point sets registration method in reverse engineering ,Computer & Industrial Engineering ,2007:270-276
[34]张春富,张军,唐文彦等,一种基于模式搜索的大尺寸测量移站坐标转换方法[J],航空计测技术,2003(6):12-14
[35]丁汉,朱利民,熊振华,复杂曲面快速测量、建模及基于点云的RP和NC加工,机械工程学报,2003,39(11):28-37
[36]李耀东,黄成祥,基于CAD模型的曲面检测方法,四川大学学报,2004,1(36):90-93
[37] Forbes A B,Harris P M,Simulated Instruments and Uncertainty Estimation [R],NPL Report,2000
[38] Savioa E,De Chifre L,An artifact for traceable free-form measurements On coordinate measuring machines[J],Precision Engineering,2002,26(1):58-60
[39] Monte-CarloSiebert,B R L,Waldele F,Kunzmann H,Assessment of uncertainties in dimensional metrology by Monte—Carlo simulation:Proposal of a modular and visual software[J],Annals of the CIRP,2000,49(1):395-398
[40]张曦,陈五一,激光跟踪仪测量曲面的测量不确定度研究[J],计量学报,2006,27(2)