复合材料薄壁回转体锥度在机测量系统的研究
摘要
复合材料零件在工业领域应用日益广泛，特别是在航空航天、汽车工业等制造领域。针对飞行器头锥这类大型复合材料薄壁回转体零件，研制并开发了复合材料薄壁回转体在机测量系统。解决了这类零件必须依赖专用测量设备测量其锥度的难题。
系统地阐述了测量系统原理，总体方案的设计及回转体零件锥度在机测量系统的重要组件。
设计构建了以工业计算机(IPC)和通用工业接口卡为核心的硬件平台。根据系统的主要功能和辅助功能要求，规划设计软件总体布局和功能模块的组织层次。
以VC++ 6.0为编程语言，开发了软件系统。软件系统功能包括点动测量、自动数据采集存储功能、数据的自动处理功能、误差补偿及可视化输出功能等。系统运行稳定，人机界面友好，智能化程度高，满足复合材料薄壁回转体在机测量的要求，在很大程度上提高了系统的柔性与自动化程度。
详细地阐述了该系统的测量方法与数据处理方案，以系统的要求与机床本身的工作特点为依据，选择有效的解决方案，提出了保持工件静止状态，分别测量多条母线，以最小二乘法评定拟合母线平面方程，多条母线锥度求均值得到工件锥度的测量方案。
深入分析探讨了测量中可能产生的误差，包括导轨直线度误差、导轨扭曲误差、光栅尺误差等等。并利用软件补偿、人为控制、以及激光干涉仪法补偿了系统的测量误差。
复合材料薄壁回转体锥度在机测量系统已成功应用于实践，并在实际测量中取得了令人满意的效果。
The application of complex material is increasing in industrial areas, especially in the manufacture of aviation and motor industrial. A new measuring instrument based on the principle for the solid of rotation such as radome has been developed and manufactured. The problem of taper test in special equipment has been solved.
The control principle and the composition of the open CNC system based on IPC in the instrument and the module of test are presented in this paper.
A kind of hardware platform, which regards IPC and industrial interface cards as the control core, is designed and constructed. According to needs of main function and auxiliary functions, the general layout of software and organizational arrangement of the function modules are planned and designed.
The software system is developed with VC++. It's composed of manual function, hand-measure function, auto-collection and auto-save function, automatic data processing function, error evaluation and visual output. The system with the character of running stably, friendly interface, high intellectualized degree, could meet the demands of radome taper measurement. Furthermore, it's highly enhanced the flexibility and the automatization of radome taper test equipment.
The measuring method and data processing are introduced in this paper. The specification of the system and machine tool are analyzed. The taper is obtained by measuring the generatrix of workpiece and fitting the line equation using the least squares techniques, then count the equalizing value of multi generatrixs.
Some key technologies for the measuring error control and error compensation are discussed, for instance, the technique of software error compensation, artificial control and test of laser interferometer.
All of the conclusions have been proved feasible through the manufacture progress.
系统地阐述了测量系统原理，总体方案的设计及回转体零件锥度在机测量系统的重要组件。
设计构建了以工业计算机(IPC)和通用工业接口卡为核心的硬件平台。根据系统的主要功能和辅助功能要求，规划设计软件总体布局和功能模块的组织层次。
以VC++ 6.0为编程语言，开发了软件系统。软件系统功能包括点动测量、自动数据采集存储功能、数据的自动处理功能、误差补偿及可视化输出功能等。系统运行稳定，人机界面友好，智能化程度高，满足复合材料薄壁回转体在机测量的要求，在很大程度上提高了系统的柔性与自动化程度。
详细地阐述了该系统的测量方法与数据处理方案，以系统的要求与机床本身的工作特点为依据，选择有效的解决方案，提出了保持工件静止状态，分别测量多条母线，以最小二乘法评定拟合母线平面方程，多条母线锥度求均值得到工件锥度的测量方案。
深入分析探讨了测量中可能产生的误差，包括导轨直线度误差、导轨扭曲误差、光栅尺误差等等。并利用软件补偿、人为控制、以及激光干涉仪法补偿了系统的测量误差。
复合材料薄壁回转体锥度在机测量系统已成功应用于实践，并在实际测量中取得了令人满意的效果。
The application of complex material is increasing in industrial areas, especially in the manufacture of aviation and motor industrial. A new measuring instrument based on the principle for the solid of rotation such as radome has been developed and manufactured. The problem of taper test in special equipment has been solved.
The control principle and the composition of the open CNC system based on IPC in the instrument and the module of test are presented in this paper.
A kind of hardware platform, which regards IPC and industrial interface cards as the control core, is designed and constructed. According to needs of main function and auxiliary functions, the general layout of software and organizational arrangement of the function modules are planned and designed.
The software system is developed with VC++. It's composed of manual function, hand-measure function, auto-collection and auto-save function, automatic data processing function, error evaluation and visual output. The system with the character of running stably, friendly interface, high intellectualized degree, could meet the demands of radome taper measurement. Furthermore, it's highly enhanced the flexibility and the automatization of radome taper test equipment.
The measuring method and data processing are introduced in this paper. The specification of the system and machine tool are analyzed. The taper is obtained by measuring the generatrix of workpiece and fitting the line equation using the least squares techniques, then count the equalizing value of multi generatrixs.
Some key technologies for the measuring error control and error compensation are discussed, for instance, the technique of software error compensation, artificial control and test of laser interferometer.
All of the conclusions have been proved feasible through the manufacture progress.
引文
[1] 周曦亚．复合材料．北京：化学工业出版社，2005．
[2] 韩俊峰，罗文广．测量学科的发展现状及展望．广西工学院学报，1999，10(3)：50-54．
[3] 伏德贵，马临泮，等．用超声测厚仪测量曲面厚度．中国工程物理研究院科技年报，1999．
[4] 张国雄．三坐标测量机．天津：天津大学出版社，1999．
[5] 宋开臣，张国雄．空间自由曲面的非接触测量．中国机械工程，1999，10(6)：661-663．
[6] Stovicek D.R. Non-contact metrology. Tooling and Production, 1993(3):13-15, 18.
[7] 李明．三坐标测量及其应用．机械工人，2002(1)：36-37．
[8] L. Finkelstein. Measurement and Instrumentation Science-Analytical Review. Measurement, 1994, (4):3-14.
[9] Park C W. An in-process flatness error measurement and compensatory control system ASME. Journal of Engineering for Industry, 1998,110.
[10] Shawky A M. In-process evaluation of workpiece geometrical tolerances in bar turning. Int. J. Mach tools Manufact, 1996, 36(1):17-31.
[11] Nishiguchi T. Improvement of productivity in aspherical precision machining with in-situ metrology. CIRP, 1991, 40(1).
[12] 张如洲．微型计算机数据采集与处理．北京工业学院出版社，1987：6-7．
[13] Saleen Iftekhar. Microprocessor Based Data Acquisition and Processing System. Data Acquisition, 1994, (3):75-77.
[14] 沈兰荪．数据采集技术．中国科学技术大学出版社，1990．
[15] 袁荣钢．三维空间精密测量系统的开发与研制．燕山大学硕士学位论文，2001．
[16] 沈尚冲．坐标转换器误差分析及其测控系统的研发．哈尔滨工业大学硕士学位论文．2003．
[17] 王桂芳．现代数控机床的测量系统．测量，2002(19)：66-68．
[18] 丁汉，朱利民，熊振华．复杂曲面快速测量建模及基于测量点云的RP和NC加工．机械工程学报，2003，39(11)：28-37．
[19] 马小丽，袁长良．锥形工件在线测量方法的研究．太原工业大学学报，1995，26(1)：69-72．
[20] 戴君，时宁．开放式数控系统的体系结构探讨．机械工程师，2000，31(7)：22-24．
[21] 卢艳军，任立义．基于几种不同操作系统平台的数控系统软件开发的比较研究．组合机床与自动化加工技术．2004，(11)：50-52．
[22] 余祥，胡力耕，卢杰持．Windows下前后台式数控软件系统．机电工程，1998，27(2)：32-34．
[23] 许残青，颜声远．数控机床人机界面设计原则初探．机床与液压，2004，12(12)：118-119．
[24] 胡育辉著．数控加工中心．北京：化学工业出版社，2005．
[25] 廉小亲著．模糊控制技术．北京：中国电力出版社，2003．
[26] 张成悌．圆柱面和圆柱面锥形度的最小二乘评定法．实用测试技术，2000，7(4)：18-20．
[27] 张成悌．锥形度的最小区域评定法．计量技术，2001(6)：23-26．
[28] 靳丽霞，钱芬．圆度及锥面跳动平台测量法．计量测试，2003(2)：38-41．
[29] 李恒熙，胡志玲．机床导轨误差对机械加工品质的影响，机械制造与研究，2006，34-36．
[30] Sourlier D, Bucher A. Surface-independent, theoretically exact bestfit for arbitrary sculptured, complex, or standard geometries. Precision Engineering, 1995, 17:101-113.
[31] Besl P J, Mckay N D. A method for registration of 3D shapes. IEEE Trans. on Pattern Analysis&Machine Intelligence, 1991, 14(2):239-256.
[32] Li Z, Gou J, Chu Y. Geometric algorithms for workpiece localization. IEEE Trans. on Robotics & Automation, 1998, 14(5):864-878.
[33] Zhang Qing, et al. The compensation technique of positioning errors of NC machine tools, Transactions of Tianjin University, 1998, 8(2):76-79.
[34] 白恩远．现代数控机床伺服及检测技术．国防工业出版社，2004，11-15．
[35] 章青．数控机床定位误差建模、参数辨识及补偿技术的研究：(博士学位论文)，天津大学，1995．
[36] 隋万涛，张丹．机床导轨直线度误差的精确评定．2007，(41)：111-112．
[37] 艾青林，吴玉厚，富大伟．零件圆柱度误差测量的现状及发展趋势．沈阳建筑工程学院学报．2001，17(1)：71-74．
[38] 杜明芳，张永明．圆锥体测量与数据处理．计测技术．2004，4：10-11．
[39] Wang Xuanze, Xie Tiebang. New automatic measurement system for cone. Harbin Institute of Technology, 2002, 1: 379-383.
[40] Prakasvudhisarn, Chakguy, Raman, Shivakumar. Framework for cone feature measurement using coordinate measuring machines. Transactions of the ASME, 2004, 126(1): 169-177.
[41] Gao, W., Kiyono, S. and Nomura, T., New multi-probemethod of roundness measurements. Precision Engng, 1996,19(1), 37-45.
[42] Gao, W. and Kiyono, S., High accuracy profile measurement of a machined surface by the combined method. Measurement, 1996, 19(1), 55 64.
[2] 韩俊峰，罗文广．测量学科的发展现状及展望．广西工学院学报，1999，10(3)：50-54．
[3] 伏德贵，马临泮，等．用超声测厚仪测量曲面厚度．中国工程物理研究院科技年报，1999．
[4] 张国雄．三坐标测量机．天津：天津大学出版社，1999．
[5] 宋开臣，张国雄．空间自由曲面的非接触测量．中国机械工程，1999，10(6)：661-663．
[6] Stovicek D.R. Non-contact metrology. Tooling and Production, 1993(3):13-15, 18.
[7] 李明．三坐标测量及其应用．机械工人，2002(1)：36-37．
[8] L. Finkelstein. Measurement and Instrumentation Science-Analytical Review. Measurement, 1994, (4):3-14.
[9] Park C W. An in-process flatness error measurement and compensatory control system ASME. Journal of Engineering for Industry, 1998,110.
[10] Shawky A M. In-process evaluation of workpiece geometrical tolerances in bar turning. Int. J. Mach tools Manufact, 1996, 36(1):17-31.
[11] Nishiguchi T. Improvement of productivity in aspherical precision machining with in-situ metrology. CIRP, 1991, 40(1).
[12] 张如洲．微型计算机数据采集与处理．北京工业学院出版社，1987：6-7．
[13] Saleen Iftekhar. Microprocessor Based Data Acquisition and Processing System. Data Acquisition, 1994, (3):75-77.
[14] 沈兰荪．数据采集技术．中国科学技术大学出版社，1990．
[15] 袁荣钢．三维空间精密测量系统的开发与研制．燕山大学硕士学位论文，2001．
[16] 沈尚冲．坐标转换器误差分析及其测控系统的研发．哈尔滨工业大学硕士学位论文．2003．
[17] 王桂芳．现代数控机床的测量系统．测量，2002(19)：66-68．
[18] 丁汉，朱利民，熊振华．复杂曲面快速测量建模及基于测量点云的RP和NC加工．机械工程学报，2003，39(11)：28-37．
[19] 马小丽，袁长良．锥形工件在线测量方法的研究．太原工业大学学报，1995，26(1)：69-72．
[20] 戴君，时宁．开放式数控系统的体系结构探讨．机械工程师，2000，31(7)：22-24．
[21] 卢艳军，任立义．基于几种不同操作系统平台的数控系统软件开发的比较研究．组合机床与自动化加工技术．2004，(11)：50-52．
[22] 余祥，胡力耕，卢杰持．Windows下前后台式数控软件系统．机电工程，1998，27(2)：32-34．
[23] 许残青，颜声远．数控机床人机界面设计原则初探．机床与液压，2004，12(12)：118-119．
[24] 胡育辉著．数控加工中心．北京：化学工业出版社，2005．
[25] 廉小亲著．模糊控制技术．北京：中国电力出版社，2003．
[26] 张成悌．圆柱面和圆柱面锥形度的最小二乘评定法．实用测试技术，2000，7(4)：18-20．
[27] 张成悌．锥形度的最小区域评定法．计量技术，2001(6)：23-26．
[28] 靳丽霞，钱芬．圆度及锥面跳动平台测量法．计量测试，2003(2)：38-41．
[29] 李恒熙，胡志玲．机床导轨误差对机械加工品质的影响，机械制造与研究，2006，34-36．
[30] Sourlier D, Bucher A. Surface-independent, theoretically exact bestfit for arbitrary sculptured, complex, or standard geometries. Precision Engineering, 1995, 17:101-113.
[31] Besl P J, Mckay N D. A method for registration of 3D shapes. IEEE Trans. on Pattern Analysis&Machine Intelligence, 1991, 14(2):239-256.
[32] Li Z, Gou J, Chu Y. Geometric algorithms for workpiece localization. IEEE Trans. on Robotics & Automation, 1998, 14(5):864-878.
[33] Zhang Qing, et al. The compensation technique of positioning errors of NC machine tools, Transactions of Tianjin University, 1998, 8(2):76-79.
[34] 白恩远．现代数控机床伺服及检测技术．国防工业出版社，2004，11-15．
[35] 章青．数控机床定位误差建模、参数辨识及补偿技术的研究：(博士学位论文)，天津大学，1995．
[36] 隋万涛，张丹．机床导轨直线度误差的精确评定．2007，(41)：111-112．
[37] 艾青林，吴玉厚，富大伟．零件圆柱度误差测量的现状及发展趋势．沈阳建筑工程学院学报．2001，17(1)：71-74．
[38] 杜明芳，张永明．圆锥体测量与数据处理．计测技术．2004，4：10-11．
[39] Wang Xuanze, Xie Tiebang. New automatic measurement system for cone. Harbin Institute of Technology, 2002, 1: 379-383.
[40] Prakasvudhisarn, Chakguy, Raman, Shivakumar. Framework for cone feature measurement using coordinate measuring machines. Transactions of the ASME, 2004, 126(1): 169-177.
[41] Gao, W., Kiyono, S. and Nomura, T., New multi-probemethod of roundness measurements. Precision Engng, 1996,19(1), 37-45.
[42] Gao, W. and Kiyono, S., High accuracy profile measurement of a machined surface by the combined method. Measurement, 1996, 19(1), 55 64.