CFETR1/32真空室机加工件的激光测量研究

在1/32真空室部件后期机加工时，采用激光跟踪仪对工件进行测量，从而解决了其在机床平台上定位基准的问题。在工件安放在机床平台后，首先通过测量拟合出工件的设计坐标系，确定其装配基准点；其次在工件外部加工出具备XY、YZ、XZ三正交平面特征的辅助标准块，建立机床坐标系；然后使用激光跟踪仪同时测量工件和辅助标准块，确定工件与辅助标准块的相对位置关系；最后机床以辅助标准块作为定位基准来完成工件的加工。使用该方法已完成两个1/32真空室部件的加工，并且加工精度在公差要求范围之内，验证了该方法的合理性和可操作性。     

CFETR 1/32����һ��ӹ����ļ�������о�

The laser tracker is used to determine the locating data of the 1/32 vacuum vessel during its later machining on the machine tool platform. Firstly, the design coordinate system of the workpiece and the base points of assembly are determined by the laser tracker when the workpiece is clamped to the platform of machining tool. Secondly, an auxiliary standard block with XY, YZ, XZ three orthogonal planes features is machined outside the workpiece to establish the machine coordinate system. Then the workpiece and auxiliary standard block are measured simultaneously with the laser tracker to determine the relative positional relationship between the workpiece and the auxiliary standard block. Finally, the machine tool uses the auxiliary standard block as the locating data to complete the machining of the workpiece. Through this method, the machining work of two 1/32 vacuum vessels have been completed, and the machining accuracy is within the range of tolerance requirements, as illustrates the rationality and practicability of the method.     

Development of a novel scattered triangulation laser probe with six linear charge-coupled devices (CCDs)

The objective of this paper is to develop an inexpensive, robust, and precise scattered-type triangulation laser probe system with six linear charge-coupled devices (CCDs), that can be used to measure simultaneously the distance and inclination angle of a workpiece surface. The developed system has been configured and assembled based on Scheimpflug's principle. Through the specific arrangement of the six linear CCDs, four different measurement modules for the developed system were possible, namely the standard triangulation probe module, the double triangulation probe module, the pentagon-like triangulation probe module, and an approximately circular triangulation probe module. Angular measurements of an inclined surface were possible using the double triangulation probe module. The measuring range of the developed laser probe was ±2 mm and the resolution was 2 μm/pixel. The performance tests among the different measurement modules of the developed probe and the commercial circular triangulation laser probe OTM3-03 have been carried out. The measurement uncertainty of the developed laser probe system, with respect to different surface roughness and slope, was generally smaller than ±20 μm within the measuring range using the pentagon-like triangulation probe module with the statistical methodology of skewness (S_k) and kurtosis (K_u) analysis by setting the appropriate threshold values for S_k and K_u, respectively. The developed probe has been integrated with a PC-based 3-axis micro-positioning stage to construct an automatic non-contact 3D measurement system and to digitize the 3D profile of a small complex object.     

Laser and electrochemical complex machining of micro-stent with on-machine three-dimensional measurement

In the micro-fabrication, small installation misalignment and deformation of the workpiece cause fatal damage. On-machine measurement is one of the efficient methods to prevent this damage. Our system performs the laser machining and the three-dimensional measurement of the workpiece position using only one laser. Based on the measurement result, the position error of the workpiece is automatically corrected and laser-machined. Electrochemical machining (ECM) is also done on the same machining system. In this paper, the configuration of the system is explained. Measurement and error correcting techniques are described in detail. And the experimental results that made stent shape using the micro-tube of diameter 120 μm and 210 μm are shown.     

Molecular dynamics simulation of subsurface deformed layers in AFM-based nanometric cutting process

Three-dimensional molecular dynamics simulations of AFM-based nanometric cutting monocrystalline copper with pin tool radius of 0.713 nm are performed to investigate the effect of uncut chip thicknesses (0.1805 nm, 0.361 nm, 0.5415 nm, 0.722 nm, 0.9025 nm, 1.0875 nm, and 1.268 nm) on the depth of subsurface deformed layers. The EAM potential and Morse potential are utilized respectively to compute the interactions between workpiece atoms, the interactions between workpiece atoms and tool atoms. The single-atom potential energy variations of the workpiece atoms within the subsurface regions during the cutting process are obtained and analyzed through a deformation criterion to determine the deformation behaviors of subsurface atoms. The simulation results reveal that the depth of subsurface deformed layers is affected by the AFM pin tool's rake angle. At each uncut chip thickness, the AFM pin tool presents different negative rake angles, consequently different degrees of deformation in the subsurface take place.     

Non-contact scanning measurement utilizing a space mapping method

In this study, a novel approach to a measuring methodology and calibration method for an optical non-contact scanning probe system is proposed and verified by experiments. The optical probe consists of a line laser diode and two charge-coupled device (CCD) cameras and is placed on a computer numerical control (CNC) machine to measure the workpiece profiles. A space mapping method using the least-squares algorithm is presented for the probe calibration and profile measurement. This method provides a simple and accurate calculation of the relationship between the real space plane and its related image space plane in a CCD camera. A transparent grid with regularly spaced nodal points is used to construct the space mapping function. The space coordinate of an object can be obtained from its image in the CCD camera via the mapping function. The measured profile data are smoothed by the B-spline blending function and can be transferred to a CAD/CAM package for industrial applications. Experimental results show that this technique can determine the 3-D profile of an object with an accuracy of 60 μm.     

A Novel Laser-Based System for Measuring Internal Thread Parameters

Based on the theory of laser measurements, we propose a novel laser-based automatic inspection system for measuring the internal thread parameters, which integrates the laser-based measuring unit to detect the longitudinal section of the thread profile and the dual-axis moving stage for the movement of an undetected object. We design a special laser probe based on the bidirectional inclination scanning method for obtaining the thread-profile data. This method and structural design enables the laser probe to overcome the shortcomings of traditional methods for measuring large inclined surfaces and eliminate the impact of the lead angle. We compare our results of internal thread-parameter measurements with the coordinate measuring machine (CMM) system and investigate the repeatability with one internal screw ring gage by the system proposed. The experimental results show that the measurement accuracy of the thread angle is 2′ and the other parameters are less than 4 μm.     

Multi-beam method to increase the stability of bridge deflection measurement

The main limitation to the accuracy of the detection of a bridge deflection using laser-based optical solutions is atmospheric turbulence because of the laser beam propagation in ground proximity. The multi-beam method is presented to increase the stability of bridge deflection measurement. It is based on the use of a four-beam optical system and a subpixel resolution algorithm for the measurement of the deflection of a laser beam that propagates through the system. To obtain accurate results, different algorithms for measuring the position of the deflected beam in different optical systems are tested and compared. Based on this comparison, the four-beam method based on the macropixels iteration centroid and four-beam optical system is selected, and an accuracy of 0.16 pixels is obtained by the determination of the beam position in our setup. The proposed method is adopted to detect the bridge deflection and an accuracy of 0.01 mm is gained when the scintillation index C_n² is 3×10⁻⁴ m^−2/3.     

一种曲线路径剪裁中刀具形变及其误差分析

动态移动切削阻力载荷对高速数控裁床加工过程中刀具形变及其剪裁误差具有的重要影响,提出了一种适用多层布料/皮革曲线剪裁路径的刀具形变及其误差计算方法;建立了动态负载条件下可伸缩刀具的挠度与转角方程,进而推导出高频振动裁刀剪裁误差及其随切削深度变化规律;计算结果表明,数控布料/皮革剪裁刀的动态载荷、高频振动参数、切削深度对剪裁误差具有重要影响,深入剖析高层数控裁床的加工机理,动态参数数据分析,对于提高机床加工效率,降低加工误差,提高刀具使用寿命具有一定的工程应用价值。     

激光扫描在工件表面检测中的应用方法

为了获取磨削工件表面特征信息，提出一种基于激光扫描的磨削工件表面检测方法。利用机械臂带动激光传感器扫描放置在激光测量平面中的磨削工件，从而获得工件在激光测量平面中的三维坐标信息，通过相邻2个扫描点之间的高度变化求出工件边界点的三维坐标信息，结合x轴和y轴坐标的极值点利用最小二乘法拟合出工件边界在激光测量平面中的解析式，进一步求出附着在工件上的坐标系相对于激光测量坐标系的位姿，最后利用工件在激光测量坐标系中的位置矢量信息得出其表面特征信息。实验结果表明，利用该方法对工件表面进行检测，得到工件表面检测误差为0.11 mm，检测平均时间在1 s内，满足工件表面特征检测要求。     

线结构激光-机器视觉三角测量光路设计

给出了线结构激光 -机器视觉三角测量的通用光路计算公式。公式考虑了激光入射角、CCD面阵与光轴的各种变化情况 ,对激光机器视觉测量系统的光路结构设计有一定的指导意义。     

3D features of modified photostructurable glass-ceramic with infrared femtosecond laser pulses

The exclusive ability of laser radiation to be focused inside transparent materials makes lasers a unique tool to process inner parts of them unreachable with other techniques. Hence, laser direct-write can be used to create 3D structures inside bulk materials. Infrared femtosecond lasers are especially indicated for this purpose because a multiphoton process is usually required for absorption and high resolution can be attained. This work studies the modifications produced by 450 fs laser pulses at 1027 nm wavelength focused inside a photostructurable glass-ceramic (Foturan^®) at different depths. Irradiated samples were submitted to standard thermal treatment and subsequent soaking in HF solution to form the buried microchannels and thus unveil the modified material. The voxel dimensions of modified material depend on the laser pulse energy and the depth at which the laser is focused. Spherical aberration and self-focusing phenomena are required to explain the observed results.     

基于激光散斑成像的零件表面粗糙度建模

表面粗糙度是衡量机械表面加工水平的重要参数. 通过构建一套激光散斑成像采集系统, 获取了不同表面加工类型和不同粗糙度值的零件表面激光散斑图像. 应用Tamura纹理特征理论提取图像的纹理粗糙度、对比度、方向度特征, 并分析了这三个特征与表面粗糙度的关系. 发现了纹理粗糙度特征与表面粗糙度的单调关系, 推导出平磨、外磨、研磨三种表面加工工艺的粗糙度值与图像纹理粗糙度特征的数学函数关系, 实现了表面粗糙度的测量. 同时, 利用Tamura纹理特征与加工工艺的依赖关系, 建立了基于贝叶斯网络的工艺识别推理模型, 推理出了零件表面加工工艺. 通过为多种加工类型表面建立粗糙度测量模型, 为粗糙度测量提供了新思路. 实验证明所提的粗糙度测量模型能以较高的准确率识别出零件表面加工类型并测量出其表面粗糙度值.     

Study on welded seam recognition using circular laser vision sensor

A novel visual robotic arc welding system based on circular laser vision sensor is developed. After image de-noising, image segmentation, and image thinning, the relation of depth value of workpiece and off-axis angle γ, three-dimensional (3D) calculation, and seam tracking experiments are carried out. Finally, the error for seam tracking system is analyzed. The results show that 1) 3D information can be obtained using the proposed visual robotic arc welding system and the real-time seam tracking is realized; 2) the seam tracking error is small enough for gas tungsten arc welding (GTAW) process, and this system can be used for seam location and seam tracking or seam finder.     

A calibration method for stereo vision sensor with large FOV based on 1D targets

Large FOV (field of view) stereo vision sensor is of great importance in the measurement of large free-form surface. Before using it, the intrinsic and structure parameters of cameras should be calibrated. Traditional methods are mainly based on planar or 3D targets, which are usually expensive and difficult to manufacture especially for large dimension ones. Compared to that the method proposed in this paper is based on 1D (one dimensional) targets, which are easy to operate and with high efficiency. First two 1D targets with multiple feature points are placed randomly, and the cameras acquire multiple images of the targets from different angles of view. With the fixed angle between vectors defined by the two 1D targets we can establish the objective function with intrinsic parameters, which can be later solved by the optimization method. Then the stereo vision sensor with two calibrated cameras is set up, which acquire multiple images of another 1D target with two feature points in unrestrained motion. The initial values of the structure parameters are estimated by the linear method for the known distance between two feature points on the 1D target, while the optimal ones and intrinsic parameters of the stereo vision sensor are estimated with non-linear optimization method by establishing the minimizing function involving all the parameters. The experimental results show that the measurement precision of the stereo vision sensor is 0.046 mm with the working distance of about 3500 mm and the measurement scale of about 4000 mm×3000 mm. The method in this paper is proved suitable for calibration of stereo vision sensor of large-scale measurement field for its easy operation and high efficiency.     

集成成像大纵深物体的三维形貌获取技术

为了满足现代工业所需的大纵深物体的三维形貌获取需求,解决传统结构光三维形貌获取技术纵深较小的问题, 借助集成成像这种阵列式多视点获取技术,构建了基于集成成像的大纵深物体的三维形貌获取技术。从集成成像原理出发,分析了集成成像三维物点和同名像点之间的关系,得到集成成像光学获取系统参数和三维物体纵深极限之间的关系。在此基础上,利用相机和电动平移台构建了扫描式相机集成成像三维形貌获取系统,并对纵深从600 mm到3 600 mm相对独立的2个物体构建的大纵深三维物体进行了形貌获取。光学实验结果显示,该集成成像大纵深物体三维形貌获取技术能够单次获取纵深为3 600 mm的三维物体的三维形貌,为大纵深物体的三维形貌获取提供了技术支持。     

线性调频半导体激光器实现大尺寸静态、动态测距

提高大型机电设备的加工水平，动态在线测量是关键。将线性调频半导体激光器应用于动态测量，对目标的位置及移动的速度、加速度等实现准实时测量，可对加工过程实现动态补偿；依靠系统的自校准，消除半导体激光器的老化对激光波长的影响，使得测量精度得以保证，进而使其实用化成为可能；待测的参数是拍频的频率，即测量精度与半导体激光器的输出光功率无关，加之频率是数字量，便于和微机相连组成自动测控系统。系统静态相对测量精度为３×１０－４。整个测量系统体积小、结构简单，便于实现生产和现场安装，可广泛应用于大型机电设备的静态、动态测量。     

Inspecting verticality of cylindrical workpieces via multi-vision sensors based on structured light

In mechanical manufacturing industry, cylindrical workpiece is one of the most commonly used type of man-made workpieces, and the verticality inspection is a very important task for guaranteeing the quality of the workpieces. In this paper, we proposed a system to inspect the verticality of cylindrical workpieces via multi-vision sensors based on structured light, which has many advantages compared with the traditional methods: fast, on-line, non-contact, flexible and remarkably more accurate. The principles and methods about how to inspect the verticality were given in details, and a real system was set up to carry out the experiments. In the system, a “sensor-unit” which consists of two stripe structured light sensors is used to address the problem of short light stripe. The experiment results indicate a high capability of the proposed system for inspecting large workpieces.     

一种新的激光车辙深度测量方法研究

车辙深度测量通常使用共梁式多路激光测距传感器测量路面多个离散点,由多个测量点组成的断面信息计算车辙深度,因横向采样点间距宽,导致测量误差较大。提出了一种新的激光车辙深度测量方法,采用线激光器和三维(3D)相机组合集成测量路面3D断面,通过3D断面解算车辙深度。3D相机以一定夹角采集激光器投射在路面的线结构光图像,获取路面的3D断面数据,对断面数据通过拉依达准则进行异常值剔除,再进行旋转、平移和模型识别,最终计算路面左右轮迹和最大车辙深度。实际证明,数据重复性和相关性都达到98%以上,与传统方法相比较,该方法采样间距小、测量精度高、成本低、通用性强,具有广阔的使用推广价值。     

Design and experimental verification of novel six-degree-of freedom geometric error measurement system for linear stage

In this study, a novel and simple measurement system for simultaneously measuring the geometric errors in six-degree-of-freedom (6-DOF) for a moving linear stage of a machine tool is designed and validated. Compared to laser interferometer and laser Doppler systems, this new measurement system is less expensive and capable of multiple functions. The proposed measurement system comprises an optics module, composed of two reflectors and two cubic beam splitters; a sensing module, composed of three two-dimensional position sensitive detectors (PSDs); and a helium-neon (He-Ne) laser. Using skew-ray tracing and a first-order Taylor series expansion, the 6-DOF geometric errors of the moving linear stage, which include translation and rotation errors, are analyzed. A laboratory prototype system is built to verify the effectiveness and accuracy of the proposed measurement system. The experimental results show that the displacement uncertainty and the angular uncertainty of the proposed measurement system are less than 1.2 µm and 0.4″, respectively. Compared with the Renishaw laser interferometer XL-80 laser system, the translational accuracy and the rotational accuracy of the proposed measurement system are less than ±1 µm and ±0.2″, respectively, when the linear stage travels 6 mm.