便携式铁道车轮外形测量仪的准确度研究
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摘要
对车轮测量精度和速度的要求是随着列车速度的增加而提高的。尽管目前的列车车轮自动检测装置可实现动态检测,但其条件是车轮必须经过特定的区域。显然,对于不便拆卸与人工移动的铁道车轮,其测量工具主要还是便携式仪器。鉴于激光三角传感器受踏面形貌、颜色及环境影响大,且价格昂贵,所以接触式扫描测量方法仍然具有最高的性价比。为此,论文就提高五连杆车轮外形测量仪准确度的相关问题,进行了全面的研究。
首先,通过对测量仪的组成、工作原理及测量程序(流程)的系统分析,建立了测量的数学模型。针对测量的全过程,分析了测量系统的误差源,采用全微分理论建立了测量误差解析模型,同时建立了全参数的MATLAB精确数值模型,利用此数值模型分析了单因素误差,多因素误差交互作用对测量结果的影响。结果表明;①各因素在所涉及的范围内完全可认为是线性独立的,这为不确定度的评定提供了依据;②两编码器的量化误差为主要的误差源,从而为仪器的标定和数据处理指明了方向。
为实现量值溯源,研究了由易到难,由粗到精,分层次,软件数值仿真与硬件测试相结合的标定/检定方法;设计了相应的标定/检定装置,研究了检定装置的检定方法。多台仪器标定实验验证了该标定方法的可行性和可靠性。标定后的仪器对JM3样板的形状测量误差小于±0.02mm。
最后,按《JJF1059—1999测量不确定度的评定与表示》及《JJF 1130-2005几何量测量设备校准中的不确定度评定指南》分析了仪器的测量不确定度,取置信概率P=0.99,包含因子k=2.58,形状参数的扩展不确定度小于±0.03mm,直径的不确定度随被测车轮直径增加而变大,但适当增加仪器尺寸后,可使测量不确定度保证在0.1mm以内。
对车轮外形测量仪准确度研究的结果表明;可通过适当的尺寸、位置参数的标定,误差补偿和正确的操作来保证仪器的测量准确度。该类型车轮外形测量仪的测量准确度能够满足高速动车的要求,该项研究具有重要的应用价值。
The train speed is highly associated with the accurency and efficiency of the measurement to the train wheel, the more it's higher, the higher the measuring requests. Although the auto-measuring equipment can realize the dynamic measure, the train wheel has to pass the given region. Obviously, the best measuring equipment is portable instrument because the train wheel is hard to move or tear down. Another, the accurency of the laser triangle sensor is influenced by the figure and color of the train wheel, environment, and the price is very high, so the contact measuring method is worthy of research. Therefor, some researches about the five-bar profilometer and how to improve the measurement accurency of the five-bar profilometer are all intruduced in the thesis.
Firstly, by analyzing the composing, operation principle and measuring process, measuring mathematical model is made. Aiming at the process of the measurement, the error sources of the measuring system are analysed, and the error analytic model of the profilometer is also made by differential theroy and the accurate parameter model by MATLAB. Furthermore, the influences to the measure result about the interacion between single-factor error and mult-factor error are analysed. The results of the analysises prove that each factor is linear and unattached, the angle of the two encoders is the biggish factor of the influences to the measure result. These results provides the gist to the demarcate methord of the incertitude and the accurency.
Secondly, to accomplish the affiliation of gauge, Calibration method which is from easy to hard, approximate to pinpoint, layered, and hardware test combination with software emulate is studied in the thesis. Testing instrument of the five-bar profilometer is designed and a simple and reasonable calibration method is set, the feasibility of the calibration method is validated by experiments. As a result of measuring JM3 model, error of shape below±0.02mm.
Finally, according to JJF1059—1999 Estimation and Demonstration of Measuring Uncertainty and JJF 1130-2005 Guide to the Estimation of Uncertainty in Calibration of Gemetrical Measuring Equipment. The measuring uncertainty of profilometer is analysed. When the believe probability is 0.99 and cover gene is 2.58, the expand uncertainty as follows,shape parameter less than±0.03mm. The uncertainty of the diameter of wheel will expand as the increase of it. However, by increasing the geometry dimension of the profilometer, we can make the uncertainty within 0.1 mm.
The study on the accurency of the five-bar profilometer indicates that it can insure the profilometer has the eligible measurement accurency by calibrating proper dimension parameters and locational parameters, compensating error and operating correctly. The measurement accurency of the five-bar profilometer can meet the requirements of the high-speed train. This study has vital pratical value.
首先,通过对测量仪的组成、工作原理及测量程序(流程)的系统分析,建立了测量的数学模型。针对测量的全过程,分析了测量系统的误差源,采用全微分理论建立了测量误差解析模型,同时建立了全参数的MATLAB精确数值模型,利用此数值模型分析了单因素误差,多因素误差交互作用对测量结果的影响。结果表明;①各因素在所涉及的范围内完全可认为是线性独立的,这为不确定度的评定提供了依据;②两编码器的量化误差为主要的误差源,从而为仪器的标定和数据处理指明了方向。
为实现量值溯源,研究了由易到难,由粗到精,分层次,软件数值仿真与硬件测试相结合的标定/检定方法;设计了相应的标定/检定装置,研究了检定装置的检定方法。多台仪器标定实验验证了该标定方法的可行性和可靠性。标定后的仪器对JM3样板的形状测量误差小于±0.02mm。
最后,按《JJF1059—1999测量不确定度的评定与表示》及《JJF 1130-2005几何量测量设备校准中的不确定度评定指南》分析了仪器的测量不确定度,取置信概率P=0.99,包含因子k=2.58,形状参数的扩展不确定度小于±0.03mm,直径的不确定度随被测车轮直径增加而变大,但适当增加仪器尺寸后,可使测量不确定度保证在0.1mm以内。
对车轮外形测量仪准确度研究的结果表明;可通过适当的尺寸、位置参数的标定,误差补偿和正确的操作来保证仪器的测量准确度。该类型车轮外形测量仪的测量准确度能够满足高速动车的要求,该项研究具有重要的应用价值。
The train speed is highly associated with the accurency and efficiency of the measurement to the train wheel, the more it's higher, the higher the measuring requests. Although the auto-measuring equipment can realize the dynamic measure, the train wheel has to pass the given region. Obviously, the best measuring equipment is portable instrument because the train wheel is hard to move or tear down. Another, the accurency of the laser triangle sensor is influenced by the figure and color of the train wheel, environment, and the price is very high, so the contact measuring method is worthy of research. Therefor, some researches about the five-bar profilometer and how to improve the measurement accurency of the five-bar profilometer are all intruduced in the thesis.
Firstly, by analyzing the composing, operation principle and measuring process, measuring mathematical model is made. Aiming at the process of the measurement, the error sources of the measuring system are analysed, and the error analytic model of the profilometer is also made by differential theroy and the accurate parameter model by MATLAB. Furthermore, the influences to the measure result about the interacion between single-factor error and mult-factor error are analysed. The results of the analysises prove that each factor is linear and unattached, the angle of the two encoders is the biggish factor of the influences to the measure result. These results provides the gist to the demarcate methord of the incertitude and the accurency.
Secondly, to accomplish the affiliation of gauge, Calibration method which is from easy to hard, approximate to pinpoint, layered, and hardware test combination with software emulate is studied in the thesis. Testing instrument of the five-bar profilometer is designed and a simple and reasonable calibration method is set, the feasibility of the calibration method is validated by experiments. As a result of measuring JM3 model, error of shape below±0.02mm.
Finally, according to JJF1059—1999 Estimation and Demonstration of Measuring Uncertainty and JJF 1130-2005 Guide to the Estimation of Uncertainty in Calibration of Gemetrical Measuring Equipment. The measuring uncertainty of profilometer is analysed. When the believe probability is 0.99 and cover gene is 2.58, the expand uncertainty as follows,shape parameter less than±0.03mm. The uncertainty of the diameter of wheel will expand as the increase of it. However, by increasing the geometry dimension of the profilometer, we can make the uncertainty within 0.1 mm.
The study on the accurency of the five-bar profilometer indicates that it can insure the profilometer has the eligible measurement accurency by calibrating proper dimension parameters and locational parameters, compensating error and operating correctly. The measurement accurency of the five-bar profilometer can meet the requirements of the high-speed train. This study has vital pratical value.
引文
[1]王彦春等.JJG(铁道)111.2-2002铁路机车、车辆轮径测量器检定规程,0-42
[2]吴学军等.轮对自动检测装置.铁道车辆,2003,(3);35-36
[3]马林.车轮踏面外形几何参数的检测技术.国外机车车辆工艺,1999,1(2);43-45
[4]高向东等.铁路车辆轮对自动检测系统的研制.机车电传动,2003,2(3);36-39
[5]冯常.车辆落轮轮对在线检测技术研究.电子科技大学,2006
[6]皮颖,冯其波等.列车车轮踏面状况动态检测系统.材料工程,2000(6)
[7]www.graw.com
[8]Coenraad Esveld.测量轮轨轮廓的有效方法.铁道机车车辆,1995,(2);63-67
[9]http;//www.iem.net
[10]上海凯力电器仪表成套有限公司.地铁车轮踏面形状检测仪,专利号98122072.X
[11]吴怀京,吴渝生.WRS2000型铁道车辆轮踏面/钢轨轨头外形快速测录诊断仪面世.仪表技术与传感器,2000,(10);46
[12]http;//www.miniprof.dk/miniprofwheel.php
[13]杨凯,王黎等.便携式轮对外形检测装置数字信号处理器的实现.光学技术,2005,31(6),898-900
[14]崔占涛,王黎,高晓蓉等.便携式轮对轮廓外形检测装置.机车车辆工艺,2004,(2);26-28.
[15]www.riftek.com
[16]柳州铁路局.外径测量仪,专利号;CN 2067817U
[17]周文祥等.车轮型面测量及手持式测量仪的研究.实用测试技术,2001(3);1-4
[18]周文祥等.铁路车轮外形曲线数字测量仪的研究.铁道学报,2005,27(5);49-53
[19]周文祥.非正交系坐标测量机及轮轨轮廓仪的研究.西南交通大学,2005.4
[20]涂军.基于并联机构的坐标测量系统研究.西南交通大学,2004.8
[21]张国雄.三坐标测量机.天津大学出版社,1999,8
[22]Lotze W.ScanMax--A novel 3D coordinate measuring machine for the shop--floor environment[J].Measurement,1996,8(1);17-25
[23]朱正德.第九届国际模具展坐标测量机展品评述.工具技术,2002,36(9);3-6
[24]吴学杰,杨晓珂.轮/轨形面测量仪.工业仪表与自动化装置,1997(5);54-56
[25]沈钢,黎冠中,李小红等.轮轨踏面外形的实际测量及几何接触的进一步研究.铁 道学报,1999,21(5);24-28
[26]Gronskov.Apparatus for the scanning of a profile and use here of US Patent No.5,351,411 October 4,1994
[27]KIKW,RSGEO,RSPROF.Programmezur Simulationder Radsatz/Gleisoder Radsatz/Rollen2Kinemat ik.Uusers Manual,Ingenieurburo Kik,1991.
[28]Josef Stock li,Bonigen,Otmar Krettek,Aachen.U bereineneue Megeratschaft zur Erfassung des Radrund Schienenp rofils undihre Software.ZET+DET Glas,1997,121(4);282-298.
[29]True H,Asmund R.The dynamics of a railway freight wagon wheelset with dry friction damping.VEHICLE SYSTEM DYNAMICS,2002,38(2);149-163.
[30]Pin Tong,Robert Greif.International Conference on Wheel/Rail Load and Disp lacement Measurement Techniques U.S.Department of Transportation,1981
[31]王彦春.铁路计量.中国计量出版社,2001.6
[32]费业泰.误差理论与数据处理.机械工业出版社,2000
[33]石则昌.机构精确度.高等教育出版社,1995
[34]李岩 花国梁等.精密测量技术.中国计量出版社,2001
[35]D.T.Pham,Sahin Yildirim。Control of trajectory of a planar robot using trcurrent hybrid network.International journal of machine tools and manufactures,1999,39;405-436.
[36]A.Y.Elatta,Li Pei Gen,Fan Liang Zhi,Yu Daoyuan,Luo Fei.An overview of robot calibration techniques,Information Technology Journal 3(1);65-73,2004.
[37]王琦.纳米三坐标测量机的精度设计与误差修正.合肥工业大学,2006.6
[38]Zhang,Getal.Error compensation of coordinate measuring machine.Ann.CIPR,1985,Vol34,P445-448
[39]Soons,J.A,Accuracy Analysis of Multi-axis Machines,PHD Thesis,Eindheven University of Technology,1993
[40]Ji Z,Li Z.Identifications of placement parameters for modular platform manipulators.Int,J.Robot.Syst.,1999
[41]Zhang H,Roth Z S.Method for Kinematic Calibration of Stewart Platforms.Int.J.Robot.Syst.,1986
[42]Zhuang H.Calibration of Stewart Platforms and Other Parallel Manipulators by Minimizing Inverse Kinematic Residuals.Int.J.Robot.Syst.,1998(1);395
[43]赵新华,张晓.三角平台并联机器人运动学参数识别.天津理工学院学报,2000
[44]Chunhe Gong,Jingxia Yuan.Nongeometric error identification and compensation for robotic system by inverse calibration,International Journal of Machhine Tools &Manufature,2000
[45]zvls.Roth,Benjamin W.Mooringetal.An Overview of Robot Calibration.IEEE Journal Robotica and Automation,1987
[46]Hanqi Zhuang.Self-Calibration of Parallel Mechanisms with a Case Study on Stewart Platforms.IEEE Transation on Robotics and Automation,1997
[47]Z.J.Geng and L.S.Haynes,"An effective kinematic calibration method for Stewart platforms," in Intel.Automat.Soft Computing,M.Jamshidi,J.Yuh,C.C.Nquyen,and Lumia,Eds.,1994,vol.2,pp.87-92
[48]裴葆青等.6UPS并联机构杆长误差标定及其对东平台运动的影响分析.控制与检测,2005
[49]刘振宇等.机器人标定技术研究.机器人,2002,(5);447-450
[50]王东署.工业机器人标定技术研究.东北大学,2005,12
[51]E.F.Fichter,"A Stewart platform-base manipulator;General theory and practical construction," Int.J.Robot.Res.,Vol.5,pp.157-182
[52]Lotze W.ScanMax-A novel 3D coordinate measuring machine for the shop-floor environment.Measurement,1996,8(1);17-25.
[53]铁路计量技术委员会.铁路专用计量检定规程汇编.铁道部标准计量研究所,2004
[54]倪育才.实用测量不确定度评定.北京计量出版社,2004
[55]倪育才.几何量测量不确定度评定.北京计量出版社,2006
[56]全国计量标准、计量检定人员考核委员会.测量不确定度评定与表示实例.中国计量出版社,2001.3
[57]国家质量技术监督局.JJF1130-2005几何量测量设备校准中的不确定度评定指南.中国计量出版社,2005.5
[2]吴学军等.轮对自动检测装置.铁道车辆,2003,(3);35-36
[3]马林.车轮踏面外形几何参数的检测技术.国外机车车辆工艺,1999,1(2);43-45
[4]高向东等.铁路车辆轮对自动检测系统的研制.机车电传动,2003,2(3);36-39
[5]冯常.车辆落轮轮对在线检测技术研究.电子科技大学,2006
[6]皮颖,冯其波等.列车车轮踏面状况动态检测系统.材料工程,2000(6)
[7]www.graw.com
[8]Coenraad Esveld.测量轮轨轮廓的有效方法.铁道机车车辆,1995,(2);63-67
[9]http;//www.iem.net
[10]上海凯力电器仪表成套有限公司.地铁车轮踏面形状检测仪,专利号98122072.X
[11]吴怀京,吴渝生.WRS2000型铁道车辆轮踏面/钢轨轨头外形快速测录诊断仪面世.仪表技术与传感器,2000,(10);46
[12]http;//www.miniprof.dk/miniprofwheel.php
[13]杨凯,王黎等.便携式轮对外形检测装置数字信号处理器的实现.光学技术,2005,31(6),898-900
[14]崔占涛,王黎,高晓蓉等.便携式轮对轮廓外形检测装置.机车车辆工艺,2004,(2);26-28.
[15]www.riftek.com
[16]柳州铁路局.外径测量仪,专利号;CN 2067817U
[17]周文祥等.车轮型面测量及手持式测量仪的研究.实用测试技术,2001(3);1-4
[18]周文祥等.铁路车轮外形曲线数字测量仪的研究.铁道学报,2005,27(5);49-53
[19]周文祥.非正交系坐标测量机及轮轨轮廓仪的研究.西南交通大学,2005.4
[20]涂军.基于并联机构的坐标测量系统研究.西南交通大学,2004.8
[21]张国雄.三坐标测量机.天津大学出版社,1999,8
[22]Lotze W.ScanMax--A novel 3D coordinate measuring machine for the shop--floor environment[J].Measurement,1996,8(1);17-25
[23]朱正德.第九届国际模具展坐标测量机展品评述.工具技术,2002,36(9);3-6
[24]吴学杰,杨晓珂.轮/轨形面测量仪.工业仪表与自动化装置,1997(5);54-56
[25]沈钢,黎冠中,李小红等.轮轨踏面外形的实际测量及几何接触的进一步研究.铁 道学报,1999,21(5);24-28
[26]Gronskov.Apparatus for the scanning of a profile and use here of US Patent No.5,351,411 October 4,1994
[27]KIKW,RSGEO,RSPROF.Programmezur Simulationder Radsatz/Gleisoder Radsatz/Rollen2Kinemat ik.Uusers Manual,Ingenieurburo Kik,1991.
[28]Josef Stock li,Bonigen,Otmar Krettek,Aachen.U bereineneue Megeratschaft zur Erfassung des Radrund Schienenp rofils undihre Software.ZET+DET Glas,1997,121(4);282-298.
[29]True H,Asmund R.The dynamics of a railway freight wagon wheelset with dry friction damping.VEHICLE SYSTEM DYNAMICS,2002,38(2);149-163.
[30]Pin Tong,Robert Greif.International Conference on Wheel/Rail Load and Disp lacement Measurement Techniques U.S.Department of Transportation,1981
[31]王彦春.铁路计量.中国计量出版社,2001.6
[32]费业泰.误差理论与数据处理.机械工业出版社,2000
[33]石则昌.机构精确度.高等教育出版社,1995
[34]李岩 花国梁等.精密测量技术.中国计量出版社,2001
[35]D.T.Pham,Sahin Yildirim。Control of trajectory of a planar robot using trcurrent hybrid network.International journal of machine tools and manufactures,1999,39;405-436.
[36]A.Y.Elatta,Li Pei Gen,Fan Liang Zhi,Yu Daoyuan,Luo Fei.An overview of robot calibration techniques,Information Technology Journal 3(1);65-73,2004.
[37]王琦.纳米三坐标测量机的精度设计与误差修正.合肥工业大学,2006.6
[38]Zhang,Getal.Error compensation of coordinate measuring machine.Ann.CIPR,1985,Vol34,P445-448
[39]Soons,J.A,Accuracy Analysis of Multi-axis Machines,PHD Thesis,Eindheven University of Technology,1993
[40]Ji Z,Li Z.Identifications of placement parameters for modular platform manipulators.Int,J.Robot.Syst.,1999
[41]Zhang H,Roth Z S.Method for Kinematic Calibration of Stewart Platforms.Int.J.Robot.Syst.,1986
[42]Zhuang H.Calibration of Stewart Platforms and Other Parallel Manipulators by Minimizing Inverse Kinematic Residuals.Int.J.Robot.Syst.,1998(1);395
[43]赵新华,张晓.三角平台并联机器人运动学参数识别.天津理工学院学报,2000
[44]Chunhe Gong,Jingxia Yuan.Nongeometric error identification and compensation for robotic system by inverse calibration,International Journal of Machhine Tools &Manufature,2000
[45]zvls.Roth,Benjamin W.Mooringetal.An Overview of Robot Calibration.IEEE Journal Robotica and Automation,1987
[46]Hanqi Zhuang.Self-Calibration of Parallel Mechanisms with a Case Study on Stewart Platforms.IEEE Transation on Robotics and Automation,1997
[47]Z.J.Geng and L.S.Haynes,"An effective kinematic calibration method for Stewart platforms," in Intel.Automat.Soft Computing,M.Jamshidi,J.Yuh,C.C.Nquyen,and Lumia,Eds.,1994,vol.2,pp.87-92
[48]裴葆青等.6UPS并联机构杆长误差标定及其对东平台运动的影响分析.控制与检测,2005
[49]刘振宇等.机器人标定技术研究.机器人,2002,(5);447-450
[50]王东署.工业机器人标定技术研究.东北大学,2005,12
[51]E.F.Fichter,"A Stewart platform-base manipulator;General theory and practical construction," Int.J.Robot.Res.,Vol.5,pp.157-182
[52]Lotze W.ScanMax-A novel 3D coordinate measuring machine for the shop-floor environment.Measurement,1996,8(1);17-25.
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