基座平面度在线测量技术研究
|
摘要
船体基座的平面度是影响船舶建造质量的重要因素之一,基座由多个分离的大小不等的平面构成,平面的几何尺寸大,部分可达10米。船体基座加工精度要求很高,通常需采用专用机床进行精密加工,不仅要在机床对基座平面进行加工前和加工完成后进行高精度平面度误差测量,在加工过程中也需要对加工点附近的平面度进行动态的在线测量,便于及时调整相关参数,以确定加工结果是否满足要求。平面度在线测量技术能够将检测和加工集成在一起,实现检测加工一体化,减少了测量时间,可在保证加工精度的前提下大大提高生产效率。
由于目前尚无现成的平面度在线测量系统可用,本文结合实际生产的需要,以误差分离技术为理论基础,设计了基于多个电涡流传感器的基座平面度在线测量系统,并根据最小条件原则对测量数据进行评定得出平面度误差值。
论文给出了基座平面度在线测量系统的整体设计方案,采用二维频域四点法进行平面度误差分离,与其它误差分离方法相比可从很大程度上减少谐波抑制的发生。采用多个电涡流传感器将位移信息转换成模拟电信号,以高速DSP芯片TMS320VC5416为核心处理器设计了数据采集处理电路,主要包括A/D转换电路、无线传输模块、显示模块和外扩Flash实现自启动等,完成了传感器组信号的A/D转换和误差分离。利用定时器中断方式控制A/D转换的采样频率达到与机床运动同步的目的,分离结果采用无线方式传输至计算机解决了现场连线复杂等问题。在计算机端利用VC设计了基座平面度评定软件,采用基于最小条件评定原则的有序判别算法得出平面度误差值,实现了人机交互。
经过实验室初步实验表明该系统的技术途径是可行的,测量精度和效率基本满足要求,达到了预期效果,为后续的现场调试与应用打下了坚实的基础。
The flatness of hall bases is one of the key factors that affect the construction quality. Hull bases are composed of many flats with different sizes, whose geometry sizes are large, some will amount to 10 meters. Requests to the machining accuracy of hull base are generally high, there usually should use special machine to accomplish the precision machining. High accuracy flatness measurement will take place not only before and after the machining process, but dynamic flatness on-line measurement around the machined points is also necessary during the course, this can be convenient to adjust some related parameters and notarize whether the machining results meet the requirements. The technology of flatness on-line measurement integrates the machining and detecting processes, realize the integration of them, reduces measuring time and greatly increases production efficiency.
At present there is not any forthcoming flatness on-line measurement system that can be available, in this paper according to practical needs, take the error separation technique as theoretical basis, and design a flatness on-line measurement system based on several eddy current displacement sensors, and carry on evaluation to the measured dates basing on least condition principle to figure out flatness error value.
This paper proposes the whole design scheme of base flatness on-line measurement, using the two-dimension frequency domain four-point method to realize the flatness error separation, which can help decrease harmonic suppression. Use several sensors to convert displacement to analog voltage signal, and design a data sampling and processing circuit taking the high speed DSP chip TMS320VC5416 as the core processor, which include A/D conversion circuit, warless transmitting module, data display module and extend a Flash memory to ensure bootloader. Finish signals' A/D conversion that from sensors and realize errors separation. Rely on timer interrupt period to control the sample frequency of A/D conversion to realize synchronization with machine. Error separation results are transmitted to computer in a wireless way in order to smooth away the line connecting difficulty. On the computer, design base flatness evaluation software, and figure out the flatness error value using the order discriminate method basing on the least condition principle, realizing human-computer interaction.
Preliminary lab experiments indicate that the technique approach of the system is feasible and measuring accuracy and efficiency achieves the expectation effect, which will lay a solid foundation for the subsequent field debugging and application.
由于目前尚无现成的平面度在线测量系统可用,本文结合实际生产的需要,以误差分离技术为理论基础,设计了基于多个电涡流传感器的基座平面度在线测量系统,并根据最小条件原则对测量数据进行评定得出平面度误差值。
论文给出了基座平面度在线测量系统的整体设计方案,采用二维频域四点法进行平面度误差分离,与其它误差分离方法相比可从很大程度上减少谐波抑制的发生。采用多个电涡流传感器将位移信息转换成模拟电信号,以高速DSP芯片TMS320VC5416为核心处理器设计了数据采集处理电路,主要包括A/D转换电路、无线传输模块、显示模块和外扩Flash实现自启动等,完成了传感器组信号的A/D转换和误差分离。利用定时器中断方式控制A/D转换的采样频率达到与机床运动同步的目的,分离结果采用无线方式传输至计算机解决了现场连线复杂等问题。在计算机端利用VC设计了基座平面度评定软件,采用基于最小条件评定原则的有序判别算法得出平面度误差值,实现了人机交互。
经过实验室初步实验表明该系统的技术途径是可行的,测量精度和效率基本满足要求,达到了预期效果,为后续的现场调试与应用打下了坚实的基础。
The flatness of hall bases is one of the key factors that affect the construction quality. Hull bases are composed of many flats with different sizes, whose geometry sizes are large, some will amount to 10 meters. Requests to the machining accuracy of hull base are generally high, there usually should use special machine to accomplish the precision machining. High accuracy flatness measurement will take place not only before and after the machining process, but dynamic flatness on-line measurement around the machined points is also necessary during the course, this can be convenient to adjust some related parameters and notarize whether the machining results meet the requirements. The technology of flatness on-line measurement integrates the machining and detecting processes, realize the integration of them, reduces measuring time and greatly increases production efficiency.
At present there is not any forthcoming flatness on-line measurement system that can be available, in this paper according to practical needs, take the error separation technique as theoretical basis, and design a flatness on-line measurement system based on several eddy current displacement sensors, and carry on evaluation to the measured dates basing on least condition principle to figure out flatness error value.
This paper proposes the whole design scheme of base flatness on-line measurement, using the two-dimension frequency domain four-point method to realize the flatness error separation, which can help decrease harmonic suppression. Use several sensors to convert displacement to analog voltage signal, and design a data sampling and processing circuit taking the high speed DSP chip TMS320VC5416 as the core processor, which include A/D conversion circuit, warless transmitting module, data display module and extend a Flash memory to ensure bootloader. Finish signals' A/D conversion that from sensors and realize errors separation. Rely on timer interrupt period to control the sample frequency of A/D conversion to realize synchronization with machine. Error separation results are transmitted to computer in a wireless way in order to smooth away the line connecting difficulty. On the computer, design base flatness evaluation software, and figure out the flatness error value using the order discriminate method basing on the least condition principle, realizing human-computer interaction.
Preliminary lab experiments indicate that the technique approach of the system is feasible and measuring accuracy and efficiency achieves the expectation effect, which will lay a solid foundation for the subsequent field debugging and application.
引文
[1]冯欣,陈晓波.一种平面度在线测量系统的研制.沈阳工业大学学报.1999,21(4):345-347.
[2]中华人民共和国国家质量监督检验检疫总局.GB/T11337—2004平面度误差检测[S].北京:国家标准出版社,2005.
[3]甘永立.几何测量公差与检测.上海:上海科学技术出版社,2005.
[4]刘丽华,张琢,张善锤.几种大平面平面度测量方法比较.宇航计测技术.1998.12,18(6):39-42.
[5]Gerd Schuchardt.Automatic,high precision flatness testing of large surfaces.Jena Review.1981,(4):154-157.
[6]Aoki,Y.,Ozono,S.,On a New Method of Roundness Measurement Based on the Three-Point Method,J.Jpn.Soc.Prec.Eng.,(in Japanese).1966,32(12):831-836
[7]梁晋文,何真,刘兴占.平面度误差分离法实时测量仪.中国,实用新型,88215251.3.
[8]蔚文平.平面度的在线检测及补偿方法的研究.航空精密制造技术.1997.33(5):40-43.
[9]葛根焰,李圣怡,吴明根.大型超精密平面度在线测量新方法.机械工艺师.1998.619-21.
[10]孙卫家.大工件平面度检测技术研究:(硕士学位论文).长春:长春理工大学,2003.
[11]张泰昌.平板检定与测量300问.北京:化学工业出版社.2006.
[12]李晓飞,张镭,李会武.几种平面度误差分离方法的分析.宇航计测技术.2006.426(2):4-7,50.
[13]魏元雷,洪迈生,叶飞帆等.平面形状误差分离方法的比较分析.航空精密制造技术.2001,37(6):33-38.
[14]NAGATA Tsutomu,O-HORI Masanori,TANI Yasuhiro et al.Ultra Precision Measurement of Straightness by Sequential Two-Point Method:Improvement of Accuracy by Data Interpolation.Transactions of the Japan Society of Mechanical Engineers.C.1991,57(542):3300-3304.
[15]ITOH Shunji,NARIKIYO Tatsuo,SATOH Yutaka,et al.Measurement of Flat Form Error by a 2-D Least Square Serial Tow Point Method,Journal of the Japan Society of Precision Engineering,(in Japanese).1991,57(10):1844-1849.
[16]陈永林.广义逆矩阵的理论与方法.南京:南京师范大学出版社,2005.
[17]祝斌,洪迈生,李济顺.基于二维Fourier变换的平面形状误差分离新方法.上海交通大学学报.1998.12,32(12):34-37.
[18]Satoshi KIYONO,Zongtao GE.Basic Study of the Measurement of 2-D Surface Profile (1st Report:Transfer Funcion and Resolution).The Japan Society of Mechanical Engineers,series C.1995,38(3):494-500.
[19]Zongtao GE.,Wei GAO,Satoshi KIYONO.Basic Study of the Measurement of 2-D Surface Profile(2nd Report:Measurement.Error Analysis).The Japan Society of Mechanical Engineers,series C.1997,38(3):439-446.
[20]洪迈生,魏元雷,李自军等.形状误差分离技术的同一理论-同源、统一的各种直线形状误差分离方法评述.宇航计测技术.2001.12 21(6):1-12.
[21]李济顺,张洛平,洪迈生.误差分离统一理论-时域频域分离一致性.计量学报.2002.7,23(3):164-166.
[22]黄富贵.平面度误差各种评定方法的比较.工具技术.2007,41(8):107-109.
[23]Muthy T.S.R.,Abdin S.Z.Minimum zone evaluation of surfaces.International journal of machine tool design&research.1980,20(2):123-136.
[24]张善锤,于瀛洁,张之江.直线度平面度测量技术.北京:中国计量出版社,1997.
[25]张之江,于瀛洁,张善锤.平面度误差最小区域新算法-有序判别法.计量学报.1998,19(1):15-21.
[26]岳武陵,吴勇,苏俊.基于最小包容区域法的平面度误差的快速评定法-新测点分类法.计量技术.2007(7):25-28.
[27]洪迈生,李自军.广义位移传感器在形状误差和误差运动分离中的读数贡献.光学技术.2002,28(6):504-507.
[28]http://www.oudan.com/OD9000.htm.
[29]Texas Instruments.TMS320VC5416 Fixed-Point Digital Signal Processor Data Manual.March 1999-Revised April 2003.
[30]TMS320C54x DSP Reference Set Vol.1:CPU and Peripherals.Texas Instruments,2001.
[31][USA]Texas Instruments Incorporated著.梁晓雯,裴小平,李玉虎 编译.TMS320VC54x 系列DSP的CPU与外设.北京:清华大学出版社,2006.
[32]张雄伟,陈亮,徐光辉.DSP芯片的原理与开发应用.北京:电子工业出版社,2003.
[33]TPS73HD301 dual-output low-dropout voltage regulator data sheet.Texas Instruments,1999.
[34]TPS3707-33 processor supervisory circuits with power-fail data sheet.Texas Instruments,1999.
[35]4-Channel,16-Bit Sampling CMOS A/D Converter ADS7825 Data sheet.Burr-Brown.com,U.S.A,1997.
[36]王云景,赵红旗,方勇军.4通道16位A/D转换器ADS7825在称量中的应用.仪表技术.2006,6:39-41.
[37]Single Chip Low Cost Low Power RF Transceiver CC1100 Data sheet.Chipcon Products from Texas Instrument,2005.
[38]孙维明,石江宏,陈岳林.可编程RF收发器CC1 100的原理及开发.国外电子元器件.2007,9:40-42.
[39]徐菲,刘同怀,黄鲁.基于Flash的TMS320VC5416 DSP系统自举实现.计算机工程与科学.2006,28(4):68-70.
[40]宗战华,郑建生.TMS320VC5416并行自举的巧妙实现.电子技术应用.2007,7:77-80.
[41]SST39VF200A Multi-Purpose Flash data sheet.Silicon Storage Technology,Inc.,2002.
[42]奉华成,白净.TMS320C54x DSP在线烧写FLASH存储器并实现自举引导的方法.电子技术应用.2005,7:72-74,77.
[43]吴建辉.印刷电路板的电磁兼容性设计.北京:国防工业出版社,2005.
[44]TMS320VC5416 Bootloader,SPRA602F[Z].Texas Instruments,2005.
[45]纪震,钟锦春,强乐.DSP系统入门与实践.北京:电子工业出版社,2006.
[46]周杰.典型数字信号处理应用中关键算法的硬件加速技术研究:(硕士学位论文).长沙:国防科技大学,2005.
[47][日]川又政征,樋口龙雄著,薛培鼎,徐国鼐译.多维数字信号处理.北京:科学出版社,2003.
[48]程佩青.数字信号处理教程.北京:清华大学出版社,2001.
[49]Texas Instruments Inc.TMS320C54x DSP Library Programmer's Reference.2004.
[50]Implementation of the Double-Precison Complex FFT for the TMS320C54X DSP,SPRA554B.Texas Instruments,1999.
[51]http://news.weeqoo.com/2007/9/2007101813057254164.html
[2]中华人民共和国国家质量监督检验检疫总局.GB/T11337—2004平面度误差检测[S].北京:国家标准出版社,2005.
[3]甘永立.几何测量公差与检测.上海:上海科学技术出版社,2005.
[4]刘丽华,张琢,张善锤.几种大平面平面度测量方法比较.宇航计测技术.1998.12,18(6):39-42.
[5]Gerd Schuchardt.Automatic,high precision flatness testing of large surfaces.Jena Review.1981,(4):154-157.
[6]Aoki,Y.,Ozono,S.,On a New Method of Roundness Measurement Based on the Three-Point Method,J.Jpn.Soc.Prec.Eng.,(in Japanese).1966,32(12):831-836
[7]梁晋文,何真,刘兴占.平面度误差分离法实时测量仪.中国,实用新型,88215251.3.
[8]蔚文平.平面度的在线检测及补偿方法的研究.航空精密制造技术.1997.33(5):40-43.
[9]葛根焰,李圣怡,吴明根.大型超精密平面度在线测量新方法.机械工艺师.1998.619-21.
[10]孙卫家.大工件平面度检测技术研究:(硕士学位论文).长春:长春理工大学,2003.
[11]张泰昌.平板检定与测量300问.北京:化学工业出版社.2006.
[12]李晓飞,张镭,李会武.几种平面度误差分离方法的分析.宇航计测技术.2006.426(2):4-7,50.
[13]魏元雷,洪迈生,叶飞帆等.平面形状误差分离方法的比较分析.航空精密制造技术.2001,37(6):33-38.
[14]NAGATA Tsutomu,O-HORI Masanori,TANI Yasuhiro et al.Ultra Precision Measurement of Straightness by Sequential Two-Point Method:Improvement of Accuracy by Data Interpolation.Transactions of the Japan Society of Mechanical Engineers.C.1991,57(542):3300-3304.
[15]ITOH Shunji,NARIKIYO Tatsuo,SATOH Yutaka,et al.Measurement of Flat Form Error by a 2-D Least Square Serial Tow Point Method,Journal of the Japan Society of Precision Engineering,(in Japanese).1991,57(10):1844-1849.
[16]陈永林.广义逆矩阵的理论与方法.南京:南京师范大学出版社,2005.
[17]祝斌,洪迈生,李济顺.基于二维Fourier变换的平面形状误差分离新方法.上海交通大学学报.1998.12,32(12):34-37.
[18]Satoshi KIYONO,Zongtao GE.Basic Study of the Measurement of 2-D Surface Profile (1st Report:Transfer Funcion and Resolution).The Japan Society of Mechanical Engineers,series C.1995,38(3):494-500.
[19]Zongtao GE.,Wei GAO,Satoshi KIYONO.Basic Study of the Measurement of 2-D Surface Profile(2nd Report:Measurement.Error Analysis).The Japan Society of Mechanical Engineers,series C.1997,38(3):439-446.
[20]洪迈生,魏元雷,李自军等.形状误差分离技术的同一理论-同源、统一的各种直线形状误差分离方法评述.宇航计测技术.2001.12 21(6):1-12.
[21]李济顺,张洛平,洪迈生.误差分离统一理论-时域频域分离一致性.计量学报.2002.7,23(3):164-166.
[22]黄富贵.平面度误差各种评定方法的比较.工具技术.2007,41(8):107-109.
[23]Muthy T.S.R.,Abdin S.Z.Minimum zone evaluation of surfaces.International journal of machine tool design&research.1980,20(2):123-136.
[24]张善锤,于瀛洁,张之江.直线度平面度测量技术.北京:中国计量出版社,1997.
[25]张之江,于瀛洁,张善锤.平面度误差最小区域新算法-有序判别法.计量学报.1998,19(1):15-21.
[26]岳武陵,吴勇,苏俊.基于最小包容区域法的平面度误差的快速评定法-新测点分类法.计量技术.2007(7):25-28.
[27]洪迈生,李自军.广义位移传感器在形状误差和误差运动分离中的读数贡献.光学技术.2002,28(6):504-507.
[28]http://www.oudan.com/OD9000.htm.
[29]Texas Instruments.TMS320VC5416 Fixed-Point Digital Signal Processor Data Manual.March 1999-Revised April 2003.
[30]TMS320C54x DSP Reference Set Vol.1:CPU and Peripherals.Texas Instruments,2001.
[31][USA]Texas Instruments Incorporated著.梁晓雯,裴小平,李玉虎 编译.TMS320VC54x 系列DSP的CPU与外设.北京:清华大学出版社,2006.
[32]张雄伟,陈亮,徐光辉.DSP芯片的原理与开发应用.北京:电子工业出版社,2003.
[33]TPS73HD301 dual-output low-dropout voltage regulator data sheet.Texas Instruments,1999.
[34]TPS3707-33 processor supervisory circuits with power-fail data sheet.Texas Instruments,1999.
[35]4-Channel,16-Bit Sampling CMOS A/D Converter ADS7825 Data sheet.Burr-Brown.com,U.S.A,1997.
[36]王云景,赵红旗,方勇军.4通道16位A/D转换器ADS7825在称量中的应用.仪表技术.2006,6:39-41.
[37]Single Chip Low Cost Low Power RF Transceiver CC1100 Data sheet.Chipcon Products from Texas Instrument,2005.
[38]孙维明,石江宏,陈岳林.可编程RF收发器CC1 100的原理及开发.国外电子元器件.2007,9:40-42.
[39]徐菲,刘同怀,黄鲁.基于Flash的TMS320VC5416 DSP系统自举实现.计算机工程与科学.2006,28(4):68-70.
[40]宗战华,郑建生.TMS320VC5416并行自举的巧妙实现.电子技术应用.2007,7:77-80.
[41]SST39VF200A Multi-Purpose Flash data sheet.Silicon Storage Technology,Inc.,2002.
[42]奉华成,白净.TMS320C54x DSP在线烧写FLASH存储器并实现自举引导的方法.电子技术应用.2005,7:72-74,77.
[43]吴建辉.印刷电路板的电磁兼容性设计.北京:国防工业出版社,2005.
[44]TMS320VC5416 Bootloader,SPRA602F[Z].Texas Instruments,2005.
[45]纪震,钟锦春,强乐.DSP系统入门与实践.北京:电子工业出版社,2006.
[46]周杰.典型数字信号处理应用中关键算法的硬件加速技术研究:(硕士学位论文).长沙:国防科技大学,2005.
[47][日]川又政征,樋口龙雄著,薛培鼎,徐国鼐译.多维数字信号处理.北京:科学出版社,2003.
[48]程佩青.数字信号处理教程.北京:清华大学出版社,2001.
[49]Texas Instruments Inc.TMS320C54x DSP Library Programmer's Reference.2004.
[50]Implementation of the Double-Precison Complex FFT for the TMS320C54X DSP,SPRA554B.Texas Instruments,1999.
[51]http://news.weeqoo.com/2007/9/2007101813057254164.html