Compensation of installation errors in a laser vision system and dimensional inspection of automobile chassis

Laser vision inspection systems are becoming popular for automated inspection of manufactured components. The performance of such systems can be enhanced by improving accuracy of the hardware and robustness of the software used in the system. This paper presents a new approach for enhancing the capability of a laser vision system by applying hardware compensation and using efficient analysis software. A 3D geometrical model is developed to study and compensate for possible distortions in installation of gantry robot on which the vision system is mounted. Appropriate compensation is applied to the inspection data obtained from the laser vision system based on the parameters in 3D model. The present laser vision system is used for dimensional inspection of car chassis sub frame and lower arm assembly module. An algorithm based on simplex search techniques is used for analyzing the compensated inspection data. The details of 3D model, parameters used for compensation and the measurement data obtained from the system are presented in this paper. The details of search algorithm used for analyzing the measurement data and the results obtained are also presented in the paper. It is observed from the results that, by applying compensation and using appropriate algorithms for analyzing, the error in evaluation of the inspection data can be significantly minimized, thus reducing the risk of rejecting good parts.     

复杂曲面零件加工精度的原位检测误差补偿方法

为提高复杂曲面零件的数控机床原位检测精度,分析影响接触式检测系统精度的各项因素及其误差补偿方法。对检测系统的主要误差来源如机床几何误差、测头预行程误差和测头半径误差进行分析研究。在对数控机床的几何误差进行分析和建模的基础上,采用激光干涉仪进行三轴数控机床的单项误差测量和补偿;针对测头检测过程中存在的预行程误差,提出基于径向基函数(Radial basis function, RBF)的预行程误差预测方法,获得测头预行程误差分布图,并对检测系统进行实时预行程误差的补偿;提出改进的三角网格模型顶点法矢计算方法,有效进行三维测头的半径补偿。通过实例零件的加工精度原位检测试验及其与三坐标测量机CMM检验结果的比较,验证了原位检测方法的有效性。     

复杂曲面零件在线检测与误差补偿方法

复杂曲面零件的高精度加工与精密检测一直是数字化制造领域的研究热点。为提高复杂曲面零件的加工精度、检测精度,提出一种集数控机床在线检测、加工误差分解与补偿加工为一体的集成化方法。介绍集成化在线检测方法及补偿系统的基本原理,分析数控加工后曲面零件测点数据的误差组成,提出一种基于空间统计分析的加工误差分解方法,在建立基于B样条曲面的确定性曲面回归模型的基础上,对回归模型残差进行空间独立性分析,分解出系统误差和随机误差,进而通过数控代码的修改,实现零件加工过程的系统误差补偿。列举一个曲面零件的加工与检测实例,进行方法有效性验证。通过加工工件的在线检测、误差分解、代码修改及补偿加工等环节,实例零件的加工精度有了大幅提高,而该系统的检测精度也通过与三坐标测量机(Coordinate measuring machine, CMM)检验结果的对比,得到了有效验证。     

Analysis of digitizing errors of a laser scanning system

The digitizing errors of a high-speed 3D laser scanning system are analyzed and characterized in this paper. As the laser scanner is an electro-optical device and based on the principle of optical triangulation, the measurement accuracy is affected by the measured part geometry and its position within the scanning window. Commercial laser scanners are often calibrated in the scanning plane to account for variation of the incident angle of the laser beam. The effects of the scan depth and the projected angle, characterizing the surface normal of the measured part external to the scanning plane, on the measurement accuracy are not considered in the standard calibration process and have been identified by experiments in the present work. Experimental results indicate that the random error of the scanned data is close to the nominal value provided by the manufacturer. The systematic error shows a bilinear relationship with the scan depth and the projected angle and has a maximum value of about 160 μm. The developed empirical model correctly predicts the systematic error with a maximum deviation of only 25 μm.     

Form-truing error compensation of diamond grinding wheel in CNC envelope grinding of free-form surface

In computer numerical control (CNC) grinding of free-form surface, an ideal arc profile of trued diamond grinding wheel is generally employed to plan 3D tool paths, whereas its form-truing errors greatly influence the ground form accuracy. A form-truing error compensation approach is proposed by using an approached wheel arc profile to replace the previously designed ideal one. The objective is to directly compensate the trued wheel arc-profile errors. It may avoid the time consumption of traditional approach that compensates the measured coordinate point errors of workpiece to an iterative grinding operation. First, the 3D tool path surface was constructed to plan the 3D tool paths. Second, the CNC arc truing of grinding wheel was conducted to analyze the form-truing error distribution relative to the applied wheel arc profile. Then, the form-truing error compensation was carried out in CNC envelope grinding. Finally, the iterative closest point (ICP) algorithm was used to match the measured coordinate points of workpiece to ideal free-form surface. It is shown that the 3D tool path surface constructed is practicable to plan arbitrary 3D tool paths for the form-truing error compensation. The ICP matching may be used to investigate 3D ground form error distribution. It is confirmed that the form-truing error compensation can directly improve the 3D ground form accuracy. It may decrease the 3D ground form error by about 20% when the 2D form-truing error is reduced by about 58% using the same truing conditions for CNC grinding.     

Rapid and accurate reverse engineering of geometry based on a multi-sensor system

The reduction of the lead time in measurement and reverse engineering, and the increased requirements in terms of accuracy and flexibility, have resulted in a great deal of research effort aimed at developing and implementing multi-sensor systems. This paper describes an effective competitive approach for using a tactile probe to compensate the data from a laser line scanner to perform accurate reverse engineering of geometric features. With the data acquired using laser scanning, intelligent feature recognition and segmentation algorithms can be exploited to extract the global surface information of the object. The tactile probe is used to re-measure the geometric features with a small number of sampling points and the obtained information can be subsequently used to compensate the point data patches which are measured by laser scanning system. Then, the compensated point data can be exploited for accurate reverse engineering of a CAD model. The limitations of each measurement system are compensated by the other. Experimental results on three parts validate the rapidity and accuracy of this multi-sensor data fusion approach.     

三维表面扫描机器人误差建模与补偿方法

对于三维表面扫描机器人系统,整个系统的测量误差主要来源于如下几个环节:机器人的本体定位误差、线结构光传感器的数据采集误差和手眼矩阵带来的误差。对于以上环节的各个部分,可以看成是局部过程。不论各个环节或部分的误差为多大,最后的误差均归结于所得到的测量数据。然而,整个系统的误差模型很难通过解析方法得到。为了提高系统的测量精度,通过微粒群径向基神经网络建立系统的误差模型,网络的输入选择激光条纹图像坐标系中的坐标,输出选择为经过迭代最近点算法配准后的最近点与测量点之间的误差。利用微粒群算法优化初始所得的神经元中心和宽度,在相同网络性能的前提下,压缩了网络的规模。在测量过程中利用所建立的误差网络模型将测量误差得以补偿,通过实际的试验验证该方法提高系统测量精度的有效性。     

Three-point method for measuring the geometric error components of linear and rotary axes based on sequential multilateration

The linear and rotary axes are fundamental parts of multi-axis machine tools. The geometric error components of the axes must be measured for motion error compensation to improve the accuracy of the machine tools. In this paper, a simple method named the three-point method is proposed to measure the geometric error of the linear and rotary axes of the machine tools using a laser tracker. A sequential multilateration method, where uncertainty is verified through simulation, is applied to measure the 3D coordinates. Three non-collinear points fixed on the stage of each axis are selected. The coordinates of these points are simultaneously measured using a laser tracker to obtain their volumetric errors by comparing these coordinates with ideal values. Numerous equations can be established using the geometric error models of each axis. The geometric error components can be obtained by solving these equations. The validity of the proposed method is verified through a series of experiments. The results indicate that the proposed method can measure the geometric error of the axes to compensate for the errors in multi-axis machine tools.     

结构光测量中相位误差的过补偿与欠补偿校正

针对现有结构光测量中采用的相位误差补偿算法存在的相位误差过补偿或欠补偿问题,提出了一种新的相位补偿误差校正算法。推导了环境光下四步相移的相位误差数学模型,解释了相位误差过补偿、欠补偿的产生原因;通过数学推导获得相位误差的解析表达式,提出了相位误差过补偿、欠补偿的校正算法。该方法通过向标定平面投射4步相移图像、16步相移图像与黑白图像获得相位误差系数;然后在8种不同环境光条件下重复这一步骤获得多组系数;最后运用参数拟合法获得相位误差数学模型的具体表达式。实验结果表明:无论在黑暗环境还是光环境下,利用该修正方法进行相位误差补偿后均可使相位精度达到0.002rad,比进行相位误差补偿前提高了8.6倍左右,比查找表(LUT)提高了2.5倍左右。该算法精度高,速度快,能有效解决相位误差过补偿、欠补偿的问题。     

Error compensation method for a gantry robot and a laser-vision sensor-based chassis module measurement system

This paper describes an error compensation method for a 3D laser measurement system based on a gantry robot used for car chassis sub-frame module dimensional inspection. The method is based on a geometrical model that describes possible distortions in gantry robot installation. Implementation of the error compensation model allows a several-fold decrease in gantry robot positioning error.     

航空相机像旋补偿双向控制中的内环补偿器设计

为解决航空相机摆扫成像过程中存在的像旋问题,采用四通道双向控制系统对像旋进行补偿。在系统中,基于鲁棒内环补偿器结构进行了内环补偿器设计。首先利用H∞混合灵敏度优化方法求解鲁棒内环补偿器中的鲁棒控制器,再结合参考模型确定系统的滤波器,进而得到系统化设计的内环补偿器。保证系统鲁棒稳定性的同时尽可能提高干扰抑制性能,进而在两者间折衷提高双向控制像旋补偿精度。实验结果显示,本方法能够有效抑制等效干扰的影响,提高消旋补偿的精度。动态扫描下位置补偿误差的最大值和均方根分别为(1.81×10~(-3))°、(5.224 74×10~(-4))°,与传统设计相比,补偿误差分别减小了41.99%、41.73%,提高了四通道双向控制系统的像旋补偿精度。     

神经网络在激光位移传感器误差补偿中的应用

为降低入射角对激光定位移传感器测量精度的影响,提出一种新型的误差补偿方法：先采用ＢＰ神经网络实现测量误差与法矢章动角和进动补偿方法可有效地提高激光位移传感器的测量精度。在此基础上,提一步提出了自由工面测量误差的补偿方法。     

基于误差补偿的加工中心在线检测软件的开发

对加工中心在线检测软件误差补偿技术进行研究，基于Windows平台开发了在线检测误差补偿软件。并对软件开发中的关键技术检测系统的几何误差模型的建立、测头误差处理技术进行了研究。可以同时对测头误差、机床几何误差进行补偿，有效地提高了在线检测精度。软件系统在MAKINO立式加工中心上进行了实验验证。     

龙门式多轴联动机床的几何误差建模

设计一台集加工、检测于一体的小型龙门式多轴联动加工系统,以实现小型或微小型零件的铣、钻、磨削加工。机床除了从结构上提高精度外,也采取了误差补偿的措施,通过对机床进行几何误差建模,得到几何误差模型,以便进行补偿,提高精度。     

复杂曲面零件加工精度原位检测系统的残余误差补偿

复杂曲面零件数控加工后直接进行原位加工精度检测和误差补偿,是实现精密产品闭环制造模式的有效途径。原位检测系统的误差来源于测量系统误差和机床运动系统误差,经相关的误差分离与误差补偿后,仍存在较大的残余误差,影响检测精度及其推广应用。针对原位检测系统的检测精度问题,开展检测系统残余误差的回归建模与补偿研究,在机床几何误差、测头半径误差以及预行程等基本误差补偿的基础上,建立基于偏最小二乘回归分析算法的误差回归模型,实现曲面零件测点法矢方向的检测数据二次补偿。在算法实现的基础上,列举复杂曲面零件进行数控加工与在线检测的试验研究。试验结果表明,二次误差补偿方法可以进一步提高原位检测系统的检测精度。     

A Novel Method of Efficient Machining Error Compensation Based on NURBS Surface Control Points Reconstruction

A novel method to improve the efficiency of error compensation in free-form surface machining based on the Non-Uniform Rational B-Splines (NURBS) surface control points reconstruction is proposed in this article. With the presented method, a relatively small number of inspection points are needed to be measured for error compensation. The machined surface is obtained by reconstructing the control points of the designed surface based on the on-machine measurement data. The machining error of the surface is obtained by calculating the difference between the machined surface and the designed one. Then a compensate surface is achieved using the mirror symmetry model and surface modification method to compensate the machining error. Experimental validation for the milling of a NURBS surface shows that the machining accuracy of the surface is improved by 62.57% through use of the proposed method.     

光固化快速成形精度影响因子的优化

为提高快速成形工艺的精度，利用Taguchi方法对影响扫描平面内成形精度的主要因子（扫描速度、线宽补偿、树脂收缩补偿系数及扫描间距），进行了优化实验研究。通过对实验结果的信号干扰比进行方差分析，发现扫描间隔、线性收缩补偿系数以及扫描速度与扫描间隔的交互作用对扫描平面内制作精度有显著影响，扫描速度与线宽补偿的交互作用及扫描速度与线性收缩补偿的交互作用对制作精度有一定的影响。针对高分辨率激光快速成形系统，得出了以扫描平面内制作精度为优化目标的制作参数的最佳组合。验证实验结果表明，最佳制作条件下制件的误差已减小到3μm，表明最佳因子组合方案是合理可行的，该参数的最佳组合可显著提高制作精度。     

基于误差模型的三轴联动加工轨迹预补偿方法

为了减小由于进给系统动态特性造成的多轴联动加工轮廓误差,提出了一种基于轮廓误差模型的三轴联动加工轨迹预补偿方法。首先建立了关于轨迹曲率、加工速率及进给系统动态特性参数的轮廓误差模型;然后根据读取的插补数据,利用轮廓误差模型实时预测三轴联动加工过程中的轮廓误差补偿向量并对加工轨迹指令进行补偿;最后通过对圆、变曲率和螺旋线轨迹的MATLAB仿真和机床加工实验,证明该补偿方法将轮廓误差减小了85%以上,可显著提高数控机床加工精度。     

2-RPaRSS并联操作手运动副间隙误差分析及补偿

针对新型3T1R并联操作手2-RPaRSS存在运动副间隙引起的定位偏差，造成操作手的实际轨迹与理论轨迹不吻合的问题，提出了一种基于自适应混合粒子群优化(AHPSO）算法的轨迹修正方法。建立操作手包含的各类运动副误差模型，在模型中将间隙误差完全等效成杆长误差；根据逆运动学方程建立并联操作手2-RPaRSS的位姿误差模型，得到关于输入、输出的微分关系式，并引入驱动杆输入角补偿量；利用粒子群优化(PSO)算法对补偿量寻优，将间隙误差补偿问题转化为求适应度极小值问题；通过混合权值自适应调整、学习因子自适应调节、混沌扰动范围自适应调节策略改进了PSO算法，得到AHPSO算法。仿真结果表明AHPSO算法性能优良，具有更好的收敛性和稳定性，对并联操作手运动副间隙误差的补偿是一种有效方法，补偿后定位精度得到了明显改善。     

车铣复合加工中心综合误差检测及补偿策略

根据五轴车铣复合加工中心的结构及其运动链构型特点,设计了综合误差检测方案。检测包括车主轴床身至铣主轴运动链的空间误差检测以及车主轴的热误差检测两部分。由于检测方案使刀具-工件之间构成了完整的运动链,解决了单纯的空间误差检测方法未考虑车主轴运动链误差影响的问题。文中同时提出了车铣复合加工中心综合误差补偿策略以及运用神经网络算法的几何误差和热误差综合补偿模型。采用分步体对角空间误差检测后,实施了空间误差补偿。补偿后四条体对角线的空间误差都明显减小,减小幅度从15.24 μm到50.83 μm,误差补偿效果从39.10%提高到78.06%。本文提出的方法极大地改善了空间误差补偿精度。