多关节式坐标测量系统的关键技术研究
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摘要
随着先进制造技术的快速发展,逆向工程作为一种快速获取物体三维模型的先进技术手段,在现场大型零、部件的几何尺寸检测、质量控制和虚拟现实等众多领域得到了广泛的应用。传统的逆向测量设备是笛卡尔式三坐标测量机,它以其成熟的技术和卓越的性能而享有“测量中心”的美誉,但由于受相互垂直的三轴导轨和安装环境的限制,难以满足工业生产中提出的多种现场测量要求。作为一种新型的多自由度非笛卡尔式坐标测量机,多关节式坐标测量臂应运而生。它以角度测量基准取代三坐标测量机的长度测量基准,具有便携性好、体积小、重量轻、运动灵活、现场测量方便、价格较便宜等优点,因此有着广阔的发展前景。
本论文主要研究内容包括多关节式坐标测量臂的机械结构、数据采集系统、运动学模型、运动学参数误差分析,系统标定方法关键问题,论文从理论和技术两个层面上在这些问题进行了系统而深入地探讨。
针对多关节式坐标测量臂的特点,设计了机械结构和数据采集系统。为了保证整个测量设备的测量精度和结构紧凑,关节旋转机构采用了高精度的滚动轴承,并尽可能地减轻旋转机构的晃动；选用滑环结构以实现无限旋转的目的,从而避免了信号线在测量臂内部绞断的问题。数据采集系统采用了先进的嵌入式系统和现场总线技术,减少了信号传输线的数量,降低了机械结构的复杂性,并且提高了数据采集系统的稳定性和可靠性。
据文献研究表明,测量臂定位误差中的95%是由所建立运动学模型的不准确所引起的。由此可见,运动学模型对测量臂的测量精度极为重要。目前国内外机构或者学者大多仍采用传统的D-H模型来作为测量臂的运动学模型,其缺陷在于它是4自由度参数模型,缺乏完备性。针对这一研究现状,本文提出建立最佳基准位姿原则,便于利用POE公式和Local POE公式来建立测量臂的运动学模型。这两个模型均是6自由度参数模型,可以较好地克服传统D-H模型的缺陷。在所建立的运动学基础上,提出关键杆长的设计原则,以避免测量空间内出现“空腔”现象。
从三个运动学模型出发,分析了测量臂的误差源成因,建立了运动学修正模型并研究了各运动学参数误差对测量精度的影响规律,为测量臂的设计和制造提供了理论依据。
为了提高测量臂的测量精度,提出了两种新颖的测量臂标定方法。这两种标定方法的特点是算法易于实现,标定过程简便。它们克服了以往标定方法中所用的优化算法复杂,矩阵病态,初值选取过于苛刻,迭代计算中的求导和求逆会引入较大的计算误差,计算的结果极有可能陷入局部最优解而得不到全局最优解等诸多问题。标定实验结果显示,标定后的测量精度可以满足测量臂的精度要求。
以上研究工作构成一整套多关节式坐标测量臂所需的关键技术,为测量臂的研发奠定了良好的理论基础和技术支持。本文在上述相关技术的基础上,还对非接触式激光扫描测头中的若干个关键技术做了分析总结和一些探索性的研究,为测量臂整合激光扫描测头作了前瞻性的技术储备。
With the rapid development of advanced manufacture technology, reverse engineering as an advanced technical means to get three-dimensional model of the objects has been widely applied in the field of large parts and components inspection, quality control and virtual reality. Coordinate measuring machine is the traditional Cartesian measurement equipment, and it is called as "Measurement Center" with its mature technology and its superior performance. Due to the constraint of three mutual perpendicular railways and installation environment. It is difficult to meet a variety of on-site measurement requirements in the industry. As a new type of multiple degree of freedom and non-Cartesian coordinate measuring machine, flexible articulated coordinate measuring arm realizes its measuring function via angle measurement, not length measurement. It has vast application and potential prospect, as it possesses the advantages of portability, compact volume, large work range, flexible movement and low price, moreover convenient to on-site measurement.
The major issue comprises mechanical structure, data acquisition system, kinematic model, error analysis and calibration technology. The dissertation systematically and deeply discusses these issues through theory and technology levels.
For the characteristics of the flexible articulated coordinate measuring arm, the mechanical structure and data acquisition system are dexterously designed. To ensure the accuracy and compactness of this measurement equipment, rotation components adopt high-precision bearings and are insured their body to reduce shaking by all means. Slip rings are utilized to realize the purpose of unlimited rotation, so as to avoid the signal line within the measuring arm to break down. Data acquisition system adopts the advanced embedded systems and field bus technology, to reduce the number of signal transmission lines, debase the complexity of the mechanical structure and improve stability and reliability of the data acquisition system.
According to a great deal of literatures, it is proved that the 95% measurement error are caused by the inaccurate kinematic model. Thus, a right kinematic model is extremely important to a measuring arm. Most institutions or scholars at home and abroad still adopt the traditional D-H model as the kinematic model of the measuring arm. But its shortcoming is that it lackes completeness as a 4 degrees of freedom parameter model. Therefore, this study proposes the principle of establishing benchmark gesture so that it is convenient to set up the kinematics model of a measuring arm via the product-of-exponentials formula and the local product-of-exponentials formula. Because the two models are the model of 6 degrees of freedom parameter, they can overcome the shortcomings of the traditional D-H model. Based on the established kinematic model, the principle of the key pole length is proposed to avoid the cavum phenomena in the measurement range.
Based on the three aforementioned models, error sources of the measuring arm are analysed, the kinematic correction models are established and the influence of each error of the kinematic parameters on measurement precision is detailedly studied, in order to provide a theoretical basis for the design and manufacture of the measuring arm.
In order to improve the measurement precision of the measuring arm, two novel calibration methods for measuring arm are presented. The advantages of two calibration methods simplifies calibration process and are easy to implement. Compared to the traditional methods, they overcome some shortcomings such as complicated algorithm, matrix ill condition, initial value sensitive, computational error caused by reverse and differential calculation and the obtainment of the local optimization without the global optimization. Calibration results show that measurement precision after calibration meets the precision requirement of the measuring arm.
These studies constitute a set of key technologies for flexible articulated coordinate measuring arm, and provide favorable theoretical foundation and technical support for developing a measuring arm. In addition, some key technologies of non-contact laser scanner are analyzed, summarized and exploringly studied to accumulate forward-looking technological reserve for integrating laser scanner into the measuring arm.
本论文主要研究内容包括多关节式坐标测量臂的机械结构、数据采集系统、运动学模型、运动学参数误差分析,系统标定方法关键问题,论文从理论和技术两个层面上在这些问题进行了系统而深入地探讨。
针对多关节式坐标测量臂的特点,设计了机械结构和数据采集系统。为了保证整个测量设备的测量精度和结构紧凑,关节旋转机构采用了高精度的滚动轴承,并尽可能地减轻旋转机构的晃动；选用滑环结构以实现无限旋转的目的,从而避免了信号线在测量臂内部绞断的问题。数据采集系统采用了先进的嵌入式系统和现场总线技术,减少了信号传输线的数量,降低了机械结构的复杂性,并且提高了数据采集系统的稳定性和可靠性。
据文献研究表明,测量臂定位误差中的95%是由所建立运动学模型的不准确所引起的。由此可见,运动学模型对测量臂的测量精度极为重要。目前国内外机构或者学者大多仍采用传统的D-H模型来作为测量臂的运动学模型,其缺陷在于它是4自由度参数模型,缺乏完备性。针对这一研究现状,本文提出建立最佳基准位姿原则,便于利用POE公式和Local POE公式来建立测量臂的运动学模型。这两个模型均是6自由度参数模型,可以较好地克服传统D-H模型的缺陷。在所建立的运动学基础上,提出关键杆长的设计原则,以避免测量空间内出现“空腔”现象。
从三个运动学模型出发,分析了测量臂的误差源成因,建立了运动学修正模型并研究了各运动学参数误差对测量精度的影响规律,为测量臂的设计和制造提供了理论依据。
为了提高测量臂的测量精度,提出了两种新颖的测量臂标定方法。这两种标定方法的特点是算法易于实现,标定过程简便。它们克服了以往标定方法中所用的优化算法复杂,矩阵病态,初值选取过于苛刻,迭代计算中的求导和求逆会引入较大的计算误差,计算的结果极有可能陷入局部最优解而得不到全局最优解等诸多问题。标定实验结果显示,标定后的测量精度可以满足测量臂的精度要求。
以上研究工作构成一整套多关节式坐标测量臂所需的关键技术,为测量臂的研发奠定了良好的理论基础和技术支持。本文在上述相关技术的基础上,还对非接触式激光扫描测头中的若干个关键技术做了分析总结和一些探索性的研究,为测量臂整合激光扫描测头作了前瞻性的技术储备。
With the rapid development of advanced manufacture technology, reverse engineering as an advanced technical means to get three-dimensional model of the objects has been widely applied in the field of large parts and components inspection, quality control and virtual reality. Coordinate measuring machine is the traditional Cartesian measurement equipment, and it is called as "Measurement Center" with its mature technology and its superior performance. Due to the constraint of three mutual perpendicular railways and installation environment. It is difficult to meet a variety of on-site measurement requirements in the industry. As a new type of multiple degree of freedom and non-Cartesian coordinate measuring machine, flexible articulated coordinate measuring arm realizes its measuring function via angle measurement, not length measurement. It has vast application and potential prospect, as it possesses the advantages of portability, compact volume, large work range, flexible movement and low price, moreover convenient to on-site measurement.
The major issue comprises mechanical structure, data acquisition system, kinematic model, error analysis and calibration technology. The dissertation systematically and deeply discusses these issues through theory and technology levels.
For the characteristics of the flexible articulated coordinate measuring arm, the mechanical structure and data acquisition system are dexterously designed. To ensure the accuracy and compactness of this measurement equipment, rotation components adopt high-precision bearings and are insured their body to reduce shaking by all means. Slip rings are utilized to realize the purpose of unlimited rotation, so as to avoid the signal line within the measuring arm to break down. Data acquisition system adopts the advanced embedded systems and field bus technology, to reduce the number of signal transmission lines, debase the complexity of the mechanical structure and improve stability and reliability of the data acquisition system.
According to a great deal of literatures, it is proved that the 95% measurement error are caused by the inaccurate kinematic model. Thus, a right kinematic model is extremely important to a measuring arm. Most institutions or scholars at home and abroad still adopt the traditional D-H model as the kinematic model of the measuring arm. But its shortcoming is that it lackes completeness as a 4 degrees of freedom parameter model. Therefore, this study proposes the principle of establishing benchmark gesture so that it is convenient to set up the kinematics model of a measuring arm via the product-of-exponentials formula and the local product-of-exponentials formula. Because the two models are the model of 6 degrees of freedom parameter, they can overcome the shortcomings of the traditional D-H model. Based on the established kinematic model, the principle of the key pole length is proposed to avoid the cavum phenomena in the measurement range.
Based on the three aforementioned models, error sources of the measuring arm are analysed, the kinematic correction models are established and the influence of each error of the kinematic parameters on measurement precision is detailedly studied, in order to provide a theoretical basis for the design and manufacture of the measuring arm.
In order to improve the measurement precision of the measuring arm, two novel calibration methods for measuring arm are presented. The advantages of two calibration methods simplifies calibration process and are easy to implement. Compared to the traditional methods, they overcome some shortcomings such as complicated algorithm, matrix ill condition, initial value sensitive, computational error caused by reverse and differential calculation and the obtainment of the local optimization without the global optimization. Calibration results show that measurement precision after calibration meets the precision requirement of the measuring arm.
These studies constitute a set of key technologies for flexible articulated coordinate measuring arm, and provide favorable theoretical foundation and technical support for developing a measuring arm. In addition, some key technologies of non-contact laser scanner are analyzed, summarized and exploringly studied to accumulate forward-looking technological reserve for integrating laser scanner into the measuring arm.
引文
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