零件多要素三维测量关键技术研究与系统开发
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摘要
制造业的发展在国民经济中占据着重要的意义，我国目前制造技术基础薄弱、创新能力不强、产品以低端为主的现状急需改变。尤其是高精度的检测技术和设备，国内技术水平远远落后于国际，已为国内企业和行业的发展带来了很大的阻碍。本论文在国家政策支持、行业和企业急需这一背景下开展在线测量设备的研究。主要针对检测项目繁多、难度大的复杂零件，进行在线检测关键技术和方法的研究。
零部件产品已有的检测技术主要包括接触式和非接触式两类。接触式测量方法以三坐标测量法、单一位移传感器测量法为代表，测量精度和重复性都较高，然而对于多要素的测量不能满足要求，主要由于三坐标测量法效率低下，单一方向位移传感器单次采样只能获得一维信息。非接触式测量以激光传感器测量法和机器视觉测量法为代表，由于激光传感器测量精度较低，机器视觉法对复杂零件进行测量时难以保证测量节拍，也无法满足在线测量的要求。
针对复杂零件多要素测量主要有两个研究方向，一是多传感器测量系统，但目前的研究大多是以三坐标测量机为主要测量手段，没有解决三坐标测量效率低下的缺陷；二是三维扫描系统，通过密集的采样可以获得高精度的数据，然而对于庞大三维点云数据如何适应在线测量的节拍要求，目前还没有适合的解决办法。因此，本论文中研究的多要素三维测量方法，着重解决多传感器系统的设计与在线三维测量的数据处理。
对复杂零件的测量首先要分析其特点，总结为两个要点即全部要素的获取和满足生产节拍要求。因此，复杂零件的测量先从要素入手，从测量方法和加工方法出发，提出了要素分组的原则。对几个典型零件进行了要素分析，并根据对典型零件测量方法的分析，提出了具有通用性的多要素测量系统的设计流程，主要包括：零件待测要素分析、待测要素分组、各部分测量方法确定、系统整体方案设计、数据处理与融合、误差评定与SPC（Statistical Process Control）分析。
论文接下来的几个部分将遵循这一设计方法对各部分依次开展研究。首先，以花键毂零件为例，对要素进行分组后，分别对内花键、端面及柱面尺寸、小孔以及周向轮廓几个部分的测量进行了方法分析并设计了测量系统。在这一部分着重分析了不同特征要素的测量方法和传感器的应用，通过大量试验确定了不同传感器的选择原则。
其次，提出了测量系统优化指标，包括系统的定位基准、传感器数目、机械系统、电控系统、测量精度、测量节拍、系统成本等多个指标。并对花键毂零件测量系统进行了整体结构设计和样机试制。
再次，针对多要素测量的大量数据和要素间的误差关系，提出了基于多传感器系统的变尺度点云数据融合方法，将三维拼接的理论与多传感器测量系统相结合，充分利用了多传感器系统，而不是只采用一个非接触传感器进行扫描。对于圆周方向上形状变化剧烈的要素采用小尺度的数据（即高分辨率）来描述，对于圆周方向上形状基本一致的要素，为了减小冗余信息，采用大尺度（即低分辨率）的数据点云来描述，最终形成零件的三维数字模型。为后续的综合误差评定提供了基础。
论文的最后，在完成零件多要素的采样与数据融合后，对零件进行误差综合分析与评定，提出了针对轮廓度、位置度等综合误差的评定方法；介绍了SPC质量过程控制系统，SPC系统作为测量系统的重要组成部分，是零件测量变被动为主动控制质量的关键一步，也是后续工作的研究重点。
The development of manufacturing means a lot to the national economy. The currentstatus that the basis of manufacturing technology is instability, the innovation ability isweak and most of products are at low-level need to be changed urgently. The huge gapbetween the international and the domestic technology of online detection, especially thecomplete sets of high-accuracy equipments, has hindered the development of theenterprises and the whole industry. In this context, researches on on-line detectingequipments will be made in this paper, principle targets are complex parts with plentydetecting elements.
There are two kinds of detection methods at present, the contact and un-contact,both can not meet the need of plenty-elements measurement. Because the contact methodrepresented by the CMM and the single-way displacement sensors have problems on theefficiency or multi-elements obtained, and the uncontact methods have problems onaccuracy and the measurement tempo.
For complex multi-elements measurement, two directions have been sdudied:multi-sensors system and three-dimensional scanning system. The existing achievementsof the first direction are most based on CMM, and do nothing to the poor efficiency. Thelast direction need to solve the conflicts between huge data and the measurement tempo.Thus, these two directions would be the focused research in this paper.
After analyses the characteristic of detection of complex parts and elements ofseveral typical parts, the paper proposed the rule of elements grouping and the designmethod of multi-elements measure system that include elements analyses, groupingelements, measurement system design for single group, measurement scheme for thewhole system, data fusion of the several elements, comprehensive error evaluation andSPC.
The paper then make research on each parts of the design method. First of all,measurement method of each groupe including the internal hub group, the contour group,the cylinder and end face group and the holes group has been designed.
Secondly, the paper proposes the optimizing index of the integrated system,completes the system design of splined hub, and finishes the prototype trial.
Thirdly, the paper proposes a data fusion method named as mutative-scale data fusion based on the multi-sensors system. This method combines the theory of multiviewconnection and the multi-sensons detection. Different scales of data have been used todescribe the target and finally form the three-dimensional digital model.
At last, the size, shape and position error evluations methods have been discussed in.The paper then makes the precision analyses of measurement system on differentelements. At last of this chapter, SPC system has been introduced as one of the key jobson future.
零部件产品已有的检测技术主要包括接触式和非接触式两类。接触式测量方法以三坐标测量法、单一位移传感器测量法为代表，测量精度和重复性都较高，然而对于多要素的测量不能满足要求，主要由于三坐标测量法效率低下，单一方向位移传感器单次采样只能获得一维信息。非接触式测量以激光传感器测量法和机器视觉测量法为代表，由于激光传感器测量精度较低，机器视觉法对复杂零件进行测量时难以保证测量节拍，也无法满足在线测量的要求。
针对复杂零件多要素测量主要有两个研究方向，一是多传感器测量系统，但目前的研究大多是以三坐标测量机为主要测量手段，没有解决三坐标测量效率低下的缺陷；二是三维扫描系统，通过密集的采样可以获得高精度的数据，然而对于庞大三维点云数据如何适应在线测量的节拍要求，目前还没有适合的解决办法。因此，本论文中研究的多要素三维测量方法，着重解决多传感器系统的设计与在线三维测量的数据处理。
对复杂零件的测量首先要分析其特点，总结为两个要点即全部要素的获取和满足生产节拍要求。因此，复杂零件的测量先从要素入手，从测量方法和加工方法出发，提出了要素分组的原则。对几个典型零件进行了要素分析，并根据对典型零件测量方法的分析，提出了具有通用性的多要素测量系统的设计流程，主要包括：零件待测要素分析、待测要素分组、各部分测量方法确定、系统整体方案设计、数据处理与融合、误差评定与SPC（Statistical Process Control）分析。
论文接下来的几个部分将遵循这一设计方法对各部分依次开展研究。首先，以花键毂零件为例，对要素进行分组后，分别对内花键、端面及柱面尺寸、小孔以及周向轮廓几个部分的测量进行了方法分析并设计了测量系统。在这一部分着重分析了不同特征要素的测量方法和传感器的应用，通过大量试验确定了不同传感器的选择原则。
其次，提出了测量系统优化指标，包括系统的定位基准、传感器数目、机械系统、电控系统、测量精度、测量节拍、系统成本等多个指标。并对花键毂零件测量系统进行了整体结构设计和样机试制。
再次，针对多要素测量的大量数据和要素间的误差关系，提出了基于多传感器系统的变尺度点云数据融合方法，将三维拼接的理论与多传感器测量系统相结合，充分利用了多传感器系统，而不是只采用一个非接触传感器进行扫描。对于圆周方向上形状变化剧烈的要素采用小尺度的数据（即高分辨率）来描述，对于圆周方向上形状基本一致的要素，为了减小冗余信息，采用大尺度（即低分辨率）的数据点云来描述，最终形成零件的三维数字模型。为后续的综合误差评定提供了基础。
论文的最后，在完成零件多要素的采样与数据融合后，对零件进行误差综合分析与评定，提出了针对轮廓度、位置度等综合误差的评定方法；介绍了SPC质量过程控制系统，SPC系统作为测量系统的重要组成部分，是零件测量变被动为主动控制质量的关键一步，也是后续工作的研究重点。
The development of manufacturing means a lot to the national economy. The currentstatus that the basis of manufacturing technology is instability, the innovation ability isweak and most of products are at low-level need to be changed urgently. The huge gapbetween the international and the domestic technology of online detection, especially thecomplete sets of high-accuracy equipments, has hindered the development of theenterprises and the whole industry. In this context, researches on on-line detectingequipments will be made in this paper, principle targets are complex parts with plentydetecting elements.
There are two kinds of detection methods at present, the contact and un-contact,both can not meet the need of plenty-elements measurement. Because the contact methodrepresented by the CMM and the single-way displacement sensors have problems on theefficiency or multi-elements obtained, and the uncontact methods have problems onaccuracy and the measurement tempo.
For complex multi-elements measurement, two directions have been sdudied:multi-sensors system and three-dimensional scanning system. The existing achievementsof the first direction are most based on CMM, and do nothing to the poor efficiency. Thelast direction need to solve the conflicts between huge data and the measurement tempo.Thus, these two directions would be the focused research in this paper.
After analyses the characteristic of detection of complex parts and elements ofseveral typical parts, the paper proposed the rule of elements grouping and the designmethod of multi-elements measure system that include elements analyses, groupingelements, measurement system design for single group, measurement scheme for thewhole system, data fusion of the several elements, comprehensive error evaluation andSPC.
The paper then make research on each parts of the design method. First of all,measurement method of each groupe including the internal hub group, the contour group,the cylinder and end face group and the holes group has been designed.
Secondly, the paper proposes the optimizing index of the integrated system,completes the system design of splined hub, and finishes the prototype trial.
Thirdly, the paper proposes a data fusion method named as mutative-scale data fusion based on the multi-sensors system. This method combines the theory of multiviewconnection and the multi-sensons detection. Different scales of data have been used todescribe the target and finally form the three-dimensional digital model.
At last, the size, shape and position error evluations methods have been discussed in.The paper then makes the precision analyses of measurement system on differentelements. At last of this chapter, SPC system has been introduced as one of the key jobson future.
引文
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