大型复杂曲面在线测量与质量评估系统的研究
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摘要
大型复杂曲面在线测量与质量评估系统,是在数控机床上集成测头和专用软件模块实现工件毛坯在线测量与加工余量估计、工件加工质量在线评估功能的系统。本课题以国家“863”项目大型舰船用螺旋桨七轴五联动车铣复合加工机床为研究背景,以大型螺旋桨为研究对象,在深入研究了大型复杂曲面在线测量与质量评估的理论及实现技术的基础上,开发出了基于七轴五联动数控系统的在线测量与质量评估系统。本文主要内容如下:
首先,详细阐述了在线测量与质量评估的原理,对大型复杂曲面在线测量与质量评估系统做了需求分析,提出了系统的总体设计方案。
然后,深入研究了在线测量与质量评估的关键技术,主要包括:
测点的规划及测量轨迹自动生成。用双三次B样条建立螺旋桨叶片曲面的CAD模型,按曲面曲率的变化进行毛坯工件测点的自适应分布规划,按其检测要求进行加工后工件测点的规划,并对所规划的测点进行了干涉判断。
叶片曲面的匹配及加工余量的计算。用最小二乘法建立曲面匹配的目标函数,并用遗传算法进行求解。在对螺旋桨找圆、找平的装卡工艺分析后,进行了简化求解。螺旋桨叶片在线质量的评估。推导了螺旋桨叶片几何参数(螺距、叶厚、叶宽、后倾角等)的计算公式。螺旋桨叶片在线质量评估是对加工完之后的工件进行在线测量,根据测量数据评估其质量。
再后,分析了七轴五联动数控系统的体系结构,规划了在线测量与质量评估软件的功能模块,选用基于内嵌OpenGL的Visual C++软件开发平台实现了该系统软件的开发,并完成了系统的集成。
最后,应用开发出的基于“数控机床+专用软件+测头”结构的大型复杂曲面在线测量与质量评估系统在七轴五联动数控机床上进行了集成和测量实验,结果表明所开发的系统简单实用,提高了叶片类零件测量和质量评估的效率和精度。
The online measuring and quality evaluating system for the large complex surface,which integrates the NC machine, probe and software together, is to perform measuring work-pieces automatically. Measuring is to match the rough work-piece with its CAD model well (Location) before machining, and to evaluate the quality of the product after machining. This subject is based on the“863”project“Seven Axis and Five-linked Turning and Milling Numerical Control Machine Tool for Manufacturing Large Marine Propeller”, researched the principle and technology of online measurement and quality evaluation for large marine propeller, and developed an online measuring and quality evaluating system. In this paper, the following researches have been done.
First, it has been studied the principle of online measurement and quality evaluation for large complex surface thoroughly, and given out the demand analysis and overall design of the system.
Secondly, key technologies of online measuring and quality evaluating for the large complex surface have been studied as following.
The measure-trajectory was planned. The propeller blade surface was modeled with double thrice B-spline method. Measure-points distribution was planned by two ways. They were adaptive distribution according to the curvature of its surface for the rough work-piece, and determination position distribution for the product work-piece. The interference measure-points were taken out and measure-path was planned.
The complex surface matching and machining allowance solving have been done. The matching function was built by the Least Squares method, and it was solved by the genetic algorithms. The function was also solved with a simplified method through the fixing craftwork of the propeller.
The quality of the propeller blades was evaluated. The blade surface geometric parameter formulas were deduced. When the machining of the propeller blade was finished, the machining surface was measured and the measure-data was gathered automatically. The machining surface geometric shape was evaluated by the data.
Thirdly, the software was developed with the development platform of OpenGL-embedded Visual C++ tool, and the system integration has been done.
Finally, the tests on the Seven Axis and Five-linked Turning and Milling Numerical Control Machine Tool have been done with the system developed. The results show that the system is very practical, and it also improves the efficiency and accuracy of measuring and quality evaluating for large blade parts.
首先,详细阐述了在线测量与质量评估的原理,对大型复杂曲面在线测量与质量评估系统做了需求分析,提出了系统的总体设计方案。
然后,深入研究了在线测量与质量评估的关键技术,主要包括:
测点的规划及测量轨迹自动生成。用双三次B样条建立螺旋桨叶片曲面的CAD模型,按曲面曲率的变化进行毛坯工件测点的自适应分布规划,按其检测要求进行加工后工件测点的规划,并对所规划的测点进行了干涉判断。
叶片曲面的匹配及加工余量的计算。用最小二乘法建立曲面匹配的目标函数,并用遗传算法进行求解。在对螺旋桨找圆、找平的装卡工艺分析后,进行了简化求解。螺旋桨叶片在线质量的评估。推导了螺旋桨叶片几何参数(螺距、叶厚、叶宽、后倾角等)的计算公式。螺旋桨叶片在线质量评估是对加工完之后的工件进行在线测量,根据测量数据评估其质量。
再后,分析了七轴五联动数控系统的体系结构,规划了在线测量与质量评估软件的功能模块,选用基于内嵌OpenGL的Visual C++软件开发平台实现了该系统软件的开发,并完成了系统的集成。
最后,应用开发出的基于“数控机床+专用软件+测头”结构的大型复杂曲面在线测量与质量评估系统在七轴五联动数控机床上进行了集成和测量实验,结果表明所开发的系统简单实用,提高了叶片类零件测量和质量评估的效率和精度。
The online measuring and quality evaluating system for the large complex surface,which integrates the NC machine, probe and software together, is to perform measuring work-pieces automatically. Measuring is to match the rough work-piece with its CAD model well (Location) before machining, and to evaluate the quality of the product after machining. This subject is based on the“863”project“Seven Axis and Five-linked Turning and Milling Numerical Control Machine Tool for Manufacturing Large Marine Propeller”, researched the principle and technology of online measurement and quality evaluation for large marine propeller, and developed an online measuring and quality evaluating system. In this paper, the following researches have been done.
First, it has been studied the principle of online measurement and quality evaluation for large complex surface thoroughly, and given out the demand analysis and overall design of the system.
Secondly, key technologies of online measuring and quality evaluating for the large complex surface have been studied as following.
The measure-trajectory was planned. The propeller blade surface was modeled with double thrice B-spline method. Measure-points distribution was planned by two ways. They were adaptive distribution according to the curvature of its surface for the rough work-piece, and determination position distribution for the product work-piece. The interference measure-points were taken out and measure-path was planned.
The complex surface matching and machining allowance solving have been done. The matching function was built by the Least Squares method, and it was solved by the genetic algorithms. The function was also solved with a simplified method through the fixing craftwork of the propeller.
The quality of the propeller blades was evaluated. The blade surface geometric parameter formulas were deduced. When the machining of the propeller blade was finished, the machining surface was measured and the measure-data was gathered automatically. The machining surface geometric shape was evaluated by the data.
Thirdly, the software was developed with the development platform of OpenGL-embedded Visual C++ tool, and the system integration has been done.
Finally, the tests on the Seven Axis and Five-linked Turning and Milling Numerical Control Machine Tool have been done with the system developed. The results show that the system is very practical, and it also improves the efficiency and accuracy of measuring and quality evaluating for large blade parts.
引文
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[5]王世刚,吕永杰,史宝王.基于AMT助检测监控系统及其误差分析.齐齐哈尔大学学报,2002,18(1):71~74
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[7] Wolf K, Roller D, Schafer D. An approach to computer-aided quality control based on 3D coordinates metrology. Journal of Material Processing Technology, 2000,107:96~110
[8] Choi W, Kurfess T, Cagant J. Sampling uncertainty in coordinate measurement data analysis. Precision Engineering,1998,22: 53~163
[9] Bernard A. Reverse engineering for rapid product development: a state of the art. SPIE: Three-dimensional Imaging. Optical Metrology and Inspection,1999,38(35):50~63
[10] Shen W, Xi N, Song M, etal. Automated CAD-guided automobile part dimension inspection. Proceedings of the IEEE International Conference on Robotics & Automation, 2000, 4:1157~1162
[11] I Ainsworth, M Ristic, D Brujic. CAD-based measurement path planning for free-form shapes using contact probes. Int J Adv Manuf Technol, 2000,16:23~31
[12]石照耀,谢华锟,费业泰.复杂曲面测量测量技术的研究综述.机械工艺师,2001,11:38~40
[13] S.Z.Li. Adaptive sampling and mesh generation.Computer-Aided Design,1995, 27(3): 235~240
[14]李明尧.逆向工程与精确设计[J] .锻压技术,2005,1:39~41
[15]杜立彬,高晓辉,吴昊等.逆向工程各关键技术的研究进展.机械制造,2004,42(478):41~45.
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[17]王建华,林其骏,乔桂芳.复杂型面测量中测头中心的轨迹曲面及测头半径的三维补偿.计量学报,1994, 15(2):108~113
[18]艾玲,王亮.三坐标测量叶片型面半径补偿技术的应用与分析.计量技术,2002, 12:22~24.
[19]张虎,姚长永,叶声华等.空间三维测量技术的研究.仪器仪表学报, 2003, 22(4)增刊:41~43
[20]吴斌,邾继贵,杨学友等.大型物体自由曲面测量技术研究.仪器仪表学报, 2003, 24(4)增刊:294~296
[21] Leica Geosystems. http://www.leica-geosystems.com.cn/product530.asp?l1=5&l2=3 &l3=0#,2006
[22] Brainy. http://www.brainyht.com.cn/products1.asp?id=432,2006
[23] Leica Geosystems. http://www.leica-geosystems.com.cn/product510.asp?l1=5&l2=1 &l3=0,2006
[24] Longsurvey.http://www.longsurvey.com/laserace.asp,2006
[25] BOLANIC0P,MAISTOROVICDV,MILACICRV. CAD/CAI integration with special focus on complex surface. Annals of CIRP,1992,41(1):535~538
[26]陈明娟,章青,刘又午等.加工中心在线检测软件开发.制造技术与机床,2003,4:52~53
[27] Fillp D. Surface Algorithm Using Bounds Derivative. CAGD, 1986, 3(4) : 295~311
[28] Piegl L, Tiller W. Curve and Surface Constructions Using Rational B-spline. CAD, 1987,19(9) :485~498
[29] IGES Organization. Initial Graphics Exchange Specification Version5.1.New York, ISO, 1991
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