Zhong Wang

Calibration of Laser Beam Direction for Inner Diameter Measuring Device

The laser triangulation method is one of the most advanced methods for large inner diameter measurement. Our research group proposed a kind of inner diameter measuring device that is principally composed of three laser displacement sensors known to be fixed in the same plane measurement position. It is necessary to calibrate the direction of the laser beams that are emitted by laser displacement sensors because they do not meet the theoretical model accurately. For the purpose of calibrating the direction of laser beams, a calibration method and mathematical model were proposed. The inner diameter measuring device is equipped with the spindle of the machine tool. The laser beams rotate and translate in the plane and constitute the rotary rays which are driven to scan the inner surface of the ring gauge. The direction calibration of the laser beams can be completed by the sensors’ distance information and corresponding data processing method. The corresponding error sources are analyzed and the validity of the method is verified. After the calibration, the measurement error of the inner diameter measuring device reduced from ±25 μm to ±15 μm and the relative error was not more than 0.011%.

A Fast Measuring Method for the Inner Diameter of Coaxial Holes

A new method for fast diameter measurement of coaxial holes is studied. The paper describes a multi-layer measuring rod that installs a single laser displacement sensor (LDS) on each layer. This method is easy to implement by rotating the measuring rod, and immune from detecting the measuring rod’s rotation angles, so all diameters of coaxial holes can be calculated by sensors’ values. While revolving, the changing angles of each sensor’s laser beams are approximately equal in the rod’s radial direction so that the over-determined nonlinear equations of multi-layer holes for fitting circles can be established. The mathematical model of the measuring rod is established, all parameters that affect the accuracy of measurement are analyzed and simulated. In the experiment, the validity of the method is verified, the inner diameter measuring precision of 28 μm is achieved by 20 μm linearity LDS. The measuring rod has advantages of convenient operation and easy manufacture, according to the actual diameters of coaxial holes, and also the varying number of holes, LDS’s mounting location can be adjusted for different parts. It is convenient for rapid diameter measurement in industrial use.

Multi-Sensor Registration in High-Precision CMM Based on a Composite Standard

Registration is a critical step in multi-sensor dimensional measurement. As the accuracy of registration directly impacts the quality of final results, a reference sphere as a common standard is problematic in high-precision registration. In this paper, a novel method based on a composite standard is proposed to fuse the multiple heterogeneous sensors in high-precision coordinate measuring machines (CMMs), which will void the drawbacks of a reference sphere. The composite standard consists of a cone and cylinder, which share a same central axis. To ensure high precision in the submicron range, or better, the standard is manufactured by an ultra-precision machine. Three features of the composite standard are inspected by three sensors: a video camera (VC), a tactile probe (TP), and a chromatic confocal displacement sensor (CC). All features will concentrate on a common point through which the relation between the three sensors will be obtained. The errors of each measurement were analyzed theoretically, and simulations and real experiments were carried out to verify the composite standard. This study demonstrates that the proposed registration method is stable and that the standard has potential use for the registration of multiple sensors in high-precision dimensional measurement.

A method of detection to the grinding wheel layer thickness based on computer vision

This paper proposed a method of detection to the grinding wheel layer thickness based on computer vision. A camera is used to capture images of grinding wheel layer on the whole circle. Forward lighting and back lighting are used to enables a clear image to be acquired. Image processing is then executed on the images captured, which consists of image preprocessing, binarization and subpixel subdivision. The aim of binarization is to help the location of a chord and the corresponding ring width. After subpixel subdivision, the thickness of the grinding layer can be calculated finally. Compared with methods usually used to detect grinding wheel wear, method in this paper can directly and quickly get the information of thickness. Also, the eccentric error and the error of pixel equivalent are discussed in this paper.

Research on key technology of the verification system of steel rule based on vision measurement

The steel rule plays an important role in quantity transmission. However, the traditional verification method of steel rule based on manual operation and reading brings about low precision and low efficiency. A machine vison based verification system of steel rule is designed referring to JJG1-1999-Verificaiton Regulation of Steel Rule [1]. What differentiates this system is that it uses a new calibration method of pixel equivalent and decontaminates the surface of steel rule. Experiments show that these two methods fully meet the requirements of the verification system. Measuring results strongly prove that these methods not only meet the precision of verification regulation, but also improve the reliability and efficiency of the verification system.

Optimization of dynamic envelope measurement system for high speed train based on monocular vision

The definition of dynamic envelope curve is the maximum limit outline caused by various adverse effects during the running process of the train. It is an important base of making railway boundaries. At present, the measurement work of dynamic envelope curve of high-speed vehicle is mainly achieved by the way of binocular vision. There are some problems of the present measuring system like poor portability, complicated process and high cost. A new measurement system based on the monocular vision measurement theory and the analysis on the test environment is designed and the measurement system parameters, the calibration of camera with wide field of view, the calibration of the laser plane are designed and optimized in this paper. The accuracy has been verified to be up to 2mm by repeated tests and experimental data analysis. The feasibility and the adaptability of the measurement system is validated. There are some advantages of the system like lower cost, a simpler measurement and data processing process, more reliable data. And the system needs no matching algorithm.

Parallelism measurement for base plate of standard artifact with multiple tactile approaches

Nowadays, as workpieces become more precise and more specialized which results in more sophisticated structures and higher accuracy for the artifacts, higher requirements have been put forward for measuring accuracy and measuring methods. As an important method to obtain the size of workpieces, coordinate measuring machine (CMM) has been widely used in many industries. In order to achieve the calibration of a self-developed CMM, it is found that the parallelism of the base plate used for fixing the standard artifact is an important factor which affects the measurement accuracy in the process of studying self-made high-precision standard artifact. And aimed to measure the parallelism of the base plate, by using the existing high-precision CMM, gauge blocks, dial gauge and marble platform with the tactile approach, three methods for parallelism measurement of workpieces are employed, and comparisons are made within the measurement results. The results of experiments show that the final accuracy of all the three methods is able to reach micron level and meets the measurement requirements. Simultaneously, these three approaches are suitable for different measurement conditions which provide a basis for rapid and high-precision measurement under different equipment conditions.

Relative position calibration of multi-LDS in shaft center measurement system

In the center measuring device consisting of a plurality of laser triangular displacement sensors (LDS) for coaxiality measurement of shaft, it fits the center coordinate of the shaft by obtaining the coordinates of the outer contour, this poses a higher requirement for the relative position calibration accuracy of the multi-LDS. Aiming at the positional relationship between multi-LDS, the CMM is leaded into the calibration of the center measuring device. Randomly moves a standard column and reading the length values of multi-LDS, combined with the known center coordinates of the column from CMM, to establish the over-determined nonlinear equations, the angle and starting position of the laser beam of each LDS in the measuring device are calculated. The experiment result indicates that measuring uncertainty of the system is 30 μm, this proved the validity and feasibility of the multi-LDS center measuring device in the use of coaxiality measurement of shaft. As a result, it is found that the proposed calibration method is accuracy to the multi-LDS center measuring device and can be implemented easily.

An in-situ measuring method for planar straightness error

According to some current problems in the course of measuring the plane shape error of workpiece, an in-situ measuring method based on laser triangulation is presented in this paper. The method avoids the inefficiency of traditional methods like knife straightedge as well as the time and cost requirements of coordinate measuring machine(CMM). A laser-based measuring head is designed and installed on the spindle of a numerical control(NC) machine. The measuring head moves in the path planning to measure measuring points. The spatial coordinates of the measuring points are obtained by the combination of the laser triangulation displacement sensor and the coordinate system of the NC machine, which could make the indicators of measurement come true. The method to evaluate planar straightness error adopts particle swarm optimization(PSO). To verify the feasibility and accuracy of the measuring method, simulation experiments were implemented with a CMM. Comparing the measurement results of measuring head with the corresponding measured values obtained by composite measuring machine, it is verified that the method can realize high-precise and automatic measurement of the planar straightness error of the workpiece.

Error analysis on squareness of multi-sensor integrated CMM for the multistep registration method

The multistep registration(MSR) method in [1] is to register two different classes of sensors deployed on z-arm of CMM(coordinate measuring machine): a video camera and a tactile probe sensor. In general, it is difficult to obtain a very precise registration result with a single common standard, instead, this method is achieved by measuring two different standards with a constant distance between them two which are fixed on a steel plate. Although many factors have been considered such as the measuring ability of sensors, the uncertainty of the machine and the number of data pairs, there is no exact analysis on the squareness between the x-axis and the y-axis on the xy plane. For this sake, error analysis on the squareness of multi-sensor integrated CMM for the multistep registration method will be made to examine the validation of the MSR method. Synthetic experiments on the squareness on the xy plane for the simplified MSR with an inclination rotation are simulated, which will lead to a regular result. Experiments have been carried out with the multi-standard device designed also in [1], meanwhile, inspections with the help of a laser interferometer on the xy plane have been carried out. The final results are conformed to the simulations, and the squareness errors of the MSR method are also similar to the results of interferometer. In other word, the MSR can also adopted/utilized to verify the squareness of a CMM.