增压器叶轮逆向工程中的关键技术研究
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摘要
作为一种新产品开发和消化、吸收先进技术的重要手段，逆向工程的研究正受到各国工业界和学术界的高度重视。随着研究的不断深入，对于一般产品的逆向而言，工业应用已经相当成熟，为此，国内外许多学者纷纷把目光投向了如何实现对复杂零件高质量、高效率的逆向工程上来，本文以此为背景，以发动机增压器叶轮的逆向为例，以高数字化效率、高尺寸精度、高曲面品质为目标展开如下研究工作。
研究了叶轮类复杂零件的数字化策略，实现了对复杂零件高精度、高效率、高安全性的数字化。首先对叶轮的结构进行了详细的分析，全面阐述了叶轮测量方式的确定、障碍物的处理、不同坐标系下测量点云的重定位、叶轮旋转轴的计算、边界棱线的测量等一系列合理的数字化策略；然后从叶轮的结构出发，从整体的角度对叶轮的测量路径进行规划，提出了基于遗传算法的多特征测量路径规划方法；最后实现了压气机叶轮的合理数字化。
研究了异常点的剔除、测量点云的重定位、半径补偿等数据预处理技术。在弦高差法的基础上，提出了全新的弦高差—比法，提高了异常点剔除的准确性和柔韧性；提出了一种基于局部图形重构的重定位方法，该方法通过对特征球的最小二乘拟合，消除了单一参考点的精度对重定位的影响；在此基础上对重定位的误差进行了详细的分析，给出了精确的误差值，从数学的角度保证了重定位的精度；在三角网格法的基础上提出了基于Delaunay三角剖分的半径补偿新方法，有效改善了补偿矢量的计算效率和准确性。
研究了基于小波分析的曲线曲面光顺技术，并将该技术拓宽到了对任意控制顶点曲线曲面的光顺。在分析B样条原理及其相应性质的基础上，用严格的数学证明，推导了半正交准均匀三次B样条小波分解重构矩阵的具体算法；为了拓宽小波光顺技术的应用范围，提出了基于任意控制顶点的半正交准均匀三次B样条小波分解重构算法，给出了精确的计算公式，以实现对具有任意控制顶点曲线曲面的小波光顺；将基于任意控制顶点的半正交准均匀三次B样条小波分解重构算法应用到了曲线曲面光顺过程中的精度控制环节，给出了控制顶点数量的指导性算法，使重构曲线曲面更容易达到品质和精度的最佳统一；最后实现了叶轮叶片各个功能曲面的合理光顺。
研究了重构曲面精度控制的定量分析技术。借鉴精度设计原理和轮廓度的概念，实现了对曲面重构误差的定量计算和有效控制；最后对增压器叶轮叶片各个功能曲面的重构精度进行了定量分析，给出了分析效果图和误差分布图。
Reverse Engineering (RE), which is applied to develop new products and to introduce advanced technologies, has received most attention both from academia and industry. With the development of RE, its industry applications for common parts are quite consummate. Recently, notable efforts have been made toward Reverse Engineering on complex parts with quality and efficiency. The major objective of this research is to realize rapid digitization, accurate surface reconstruction and perfect surface quality of the engine supercharger impeller.
Digitization strategies of complex parts like an impeller are studied, so accurate, efficient, secure digitization is realized in this thesis. The structure of the impeller in engine supercharger, firstly, is systemically analyzed. A series of digitization strategies including equipment selection, stumbling block avoidance, registration, rotation axes computation and borderline measurement are presented. Secondly, based on the structure of the impeller, a GA-Based the Multi-Character Inspection Path Planning on CMM is proposed. Finally, digitization of the impeller is realized.
Data pre-processing technologies such as singular points elimination, registration and radius compensation are studied. Base on chord high difference algorithm, a new one called chord high difference-ratio algorithm is proposed to improve veracity and robusticity of singular points elimination. Then, a registration algorithm based on local surface reconstruction is proposed, which avoids infaust influence coming from single reference point error. Furthermore, error of registration is accurately calculated. A new radius compensation algorithm based on Delaunay triangulation is presented, which can improve calculation efficiency and veracity of compensation vector.
Wavelet fairing technology is studied and introduced into fair Quadi-Uniform Cubic B-Spline curve and surface with arbitrary number of vertexes. Based on B-spline theory and its properties, a decomposition and reconstruction algorithm of semi-orthogonal B-spline wavelets is presented by strict mathematical deduction. Because of its limitation to vertex number, an arbitrary resolution wavelet decomposition and reconstruction algorithm is proposed and applied to curve and surface fairing. This technology can also be used to control precision when curve and surface are faired and achieves best combination between quality and precision. Consequently, the supercharger impeller functionality
研究了叶轮类复杂零件的数字化策略，实现了对复杂零件高精度、高效率、高安全性的数字化。首先对叶轮的结构进行了详细的分析，全面阐述了叶轮测量方式的确定、障碍物的处理、不同坐标系下测量点云的重定位、叶轮旋转轴的计算、边界棱线的测量等一系列合理的数字化策略；然后从叶轮的结构出发，从整体的角度对叶轮的测量路径进行规划，提出了基于遗传算法的多特征测量路径规划方法；最后实现了压气机叶轮的合理数字化。
研究了异常点的剔除、测量点云的重定位、半径补偿等数据预处理技术。在弦高差法的基础上，提出了全新的弦高差—比法，提高了异常点剔除的准确性和柔韧性；提出了一种基于局部图形重构的重定位方法，该方法通过对特征球的最小二乘拟合，消除了单一参考点的精度对重定位的影响；在此基础上对重定位的误差进行了详细的分析，给出了精确的误差值，从数学的角度保证了重定位的精度；在三角网格法的基础上提出了基于Delaunay三角剖分的半径补偿新方法，有效改善了补偿矢量的计算效率和准确性。
研究了基于小波分析的曲线曲面光顺技术，并将该技术拓宽到了对任意控制顶点曲线曲面的光顺。在分析B样条原理及其相应性质的基础上，用严格的数学证明，推导了半正交准均匀三次B样条小波分解重构矩阵的具体算法；为了拓宽小波光顺技术的应用范围，提出了基于任意控制顶点的半正交准均匀三次B样条小波分解重构算法，给出了精确的计算公式，以实现对具有任意控制顶点曲线曲面的小波光顺；将基于任意控制顶点的半正交准均匀三次B样条小波分解重构算法应用到了曲线曲面光顺过程中的精度控制环节，给出了控制顶点数量的指导性算法，使重构曲线曲面更容易达到品质和精度的最佳统一；最后实现了叶轮叶片各个功能曲面的合理光顺。
研究了重构曲面精度控制的定量分析技术。借鉴精度设计原理和轮廓度的概念，实现了对曲面重构误差的定量计算和有效控制；最后对增压器叶轮叶片各个功能曲面的重构精度进行了定量分析，给出了分析效果图和误差分布图。
Reverse Engineering (RE), which is applied to develop new products and to introduce advanced technologies, has received most attention both from academia and industry. With the development of RE, its industry applications for common parts are quite consummate. Recently, notable efforts have been made toward Reverse Engineering on complex parts with quality and efficiency. The major objective of this research is to realize rapid digitization, accurate surface reconstruction and perfect surface quality of the engine supercharger impeller.
Digitization strategies of complex parts like an impeller are studied, so accurate, efficient, secure digitization is realized in this thesis. The structure of the impeller in engine supercharger, firstly, is systemically analyzed. A series of digitization strategies including equipment selection, stumbling block avoidance, registration, rotation axes computation and borderline measurement are presented. Secondly, based on the structure of the impeller, a GA-Based the Multi-Character Inspection Path Planning on CMM is proposed. Finally, digitization of the impeller is realized.
Data pre-processing technologies such as singular points elimination, registration and radius compensation are studied. Base on chord high difference algorithm, a new one called chord high difference-ratio algorithm is proposed to improve veracity and robusticity of singular points elimination. Then, a registration algorithm based on local surface reconstruction is proposed, which avoids infaust influence coming from single reference point error. Furthermore, error of registration is accurately calculated. A new radius compensation algorithm based on Delaunay triangulation is presented, which can improve calculation efficiency and veracity of compensation vector.
Wavelet fairing technology is studied and introduced into fair Quadi-Uniform Cubic B-Spline curve and surface with arbitrary number of vertexes. Based on B-spline theory and its properties, a decomposition and reconstruction algorithm of semi-orthogonal B-spline wavelets is presented by strict mathematical deduction. Because of its limitation to vertex number, an arbitrary resolution wavelet decomposition and reconstruction algorithm is proposed and applied to curve and surface fairing. This technology can also be used to control precision when curve and surface are faired and achieves best combination between quality and precision. Consequently, the supercharger impeller functionality
引文
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