Adaptive sampling for corrugated plate digitization using a laser displacement sensor

The surface quality of a corrugated plate directly determines the heat transfer property of the thermal power mechanical apparatus.Traditional detection methods are impractical for real-world production,being slow and destructive.In contrast,the point laser displacement sensor,employing the optical triangle method,emerges as a promising device for assessing parts with variable curvature and highly reflective surfaces.Despite its benefits,high-density sampling by an innate frequency introduces challenges such as data redundancy and a poor signal-to-noise ratio,potentially affecting the efficiency and precision of subsequent data processing.To address these challenges,adjustable frequency data sampling has been developed for this sensor,allowing adaptive sampling for corrugated plate digitization.The process begins with surface digitization to extract discrete points,which are transformed into intersection curves using the B-spline fitting technique.Subsequently,dominant points are identified,considering multigeometric constraints for curvature and arch height.Finally,the sampling signal is adjusted based on the distribution information of dominant points.Comparative results indicate that the proposed method effectively minimizes redundant sampling without compromising the accurate capture of essential geometric features.

LDSR激光测距传感器的研制及其用于工业检测的若干问题

本文介绍了中科院合肥智能所研制的ＬＤＳＲ激光测距传感器，其主要性能指标达到目前国际上同类产品的先进水平，且配备与计算机通讯的标准接口，可直接输出对应于检测距离的数字量值和模拟量值．

IABC: An iteratively automatic machine learning boosted hand-eye calibration method for laser displacement sensor

An on-machine measuring(OMM)system with a laser displacement sensor(LDS)is designed for measuring free-form surfaces of hypersonic aircraft’s radomes.To improve the measurement accuracy of the OMM system,a novel Iteratively Automatic machine learning Boosted hand-eye Calibration(IABC)method is proposed.Both the hand-eye relationship and LDS measurement errors can be calibrated in one calibration process without any hardware changes via IABC.Firstly,a new objective function is derived,containing analytical parameters of the handeye relationship and LDS errors.Then,a hybrid calibration model composed of two kernels is proposed to solve the objective function.One kernel is the analytical kernel designed for solving analytical parameters.Another kernel is the automatic machine learning(AutoML)kernel designed to model LDS errors.The two kernels are connected with stepwise iterations to find the best calibration results.Compared with traditional methods,hand-eye experiments show that IABC reduces the calibration RMSE by about 50%.Verification experiments show that IABC reduces the measurement deviations by about 25%-50%and RMSEs within 40%.Even when the training data are obviously less than the test data,IABC performs well.Experiments demonstrate that IABC is more accurate than traditional hand-eye methods.

基于线激光的压缩机曲轴圆度和平面度测量

目前人工使用千分表测量空调压缩机曲轴圆度和平面度时存在易伤工件表面、效率低和不能精确评定等问题。针对上述问题,设计了一套基于线激光位移传感器的空调压缩机曲轴圆度和平面度非接触式测量系统。首先,通过测量标准量棒,提出一种系统误差的标定方法;其次,基于线激光采样数据,开发了一种曲轴横截面圆度测点的提取算法,并将系统误差用于测点补偿,实现曲轴圆度测量;接着根据曲轴平面测点间的斜率分离出轮廓线,通过均匀下采样方法获取精简点云数据并采用最小二乘法实现曲轴平面度测量;最后,基于上述方法开展了曲轴圆度和平面度的测量实验。实验结果表明:该测量系统的圆度测量精度<4μm,平面度测量精度<2μm,圆度重复度测量误差<0.8μm,平面度重复度测量误差<0.3μm,满足曲轴圆度和平面度快速准确的测量需求。

室内墙面滚涂机器人结构设计和检测方法研究

针对解决室内墙面人工滚涂劳动强度大的问题,设计了一套自动化室内墙面滚涂机器人。对机器人需求功能进行结构设计,其移动载车在地面多方向移动,其机械臂提升柱将UR机械臂举升至目标位置,使用UR机械臂末端的滚筒进行墙面滚涂,对其中关键承载零件进行有限元分析;使用激光位移传感器对滚涂之后的墙面进行测量,测量数据传输至上位机处理;最后,可视化滚涂层数据并计算平面度,对于平面度不满足要求的墙面进行打磨,以提高室内装修的滚涂质量。

基于物理水平基准的组合式高程测量方法

针对空间坐标点相对于测量基准的高程测量准确性问题,提出一种基于物理水平基准的组合式高程测量方法。利用激光三角测量原理及其测量光路的几何特性,搭建了物理水平基准的高程测量系统,在朗伯散射光场中,分析了倾角变化对激光光能质心偏移量的影响,建立了相应的误差修正模型,利用倾角传感器实现了高程测量的倾角误差补偿,自主研制了标定平台对本文提出的高程测量系统进行标定验证试验。结果表明:本文提出的组合式高程测量方法能够在500 mm测量量程下将重复性测量误差控制在±20μm的波动范围内,相较于单一激光位移传感器测量方式,其组合式高程测量误差波动量大幅度降低,能够适应空间坐标点在任意姿态下的精准测量,有效改善激光位移传感器在高程测量领域的性能,使其测量结果更为真实有效。

LD温度控制系统在光纤磁场传感器中的应用

光纤磁场传感器所使用的磁光晶体的法拉第旋转角会随着入射光波长的不同而不同,半导体激光器的工作温度对输出波长有很大影响。因此,必须对半导体激光器的工作温度进行高准确度的控制才能使光纤磁场传感器工作稳定。利用单片机驱动半导体致冷器对半导体激光器进行温度控制,不仅简单,而且温度控制稳定、准确度高。可使半导体激光器的输出波长保持稳定,保证了光纤磁场传感器的测量准确度。

基于激光位移传感器的厚度测量校准系统设计及应用

为了提高钢板厚度校准的精度和安全性,针对传统接触式测厚仪精度低和射线类测厚仪存在辐射风险的问题,设计了一种基于激光位移传感器的差分非接触厚度测量校准系统。该系统采用差分测量结构,将激光位移传感器分别放置在待测钢板的顶部和底部,通过对传感器数据的采样和计算,实现钢板厚度的准确测量。硬件电路方面采用了STM32核心芯片进行设计,系统软件部分进行了相应的优化设计。试验后,系统重复性精度可达±0.1%,测量允许误差优于±0.05%,同时测量漂移控制在钢板厚度的±0.1%范围内。该系统不仅显著提高了测量精度,同时有效降低了测量过程中的安全风险,在钢板生产和加工领域具有重要的指导意义和应用价值。

基于激光传感器的滤棒长度高速在线检测系统

为解决滤棒生产过程中,滤棒长度无法实时监控的问题,本文提出采用两台激光位移传感器的非接触式测量方式,建立滤棒长度的理论计算模型,设计由激光位移传感器、工控机、PLC、人机交互界面等组成的滤棒长度高速在线检测系统,实现了滤棒长度的在线检测、检测数据存储、不合格品剔除报警。测试结果表明:该系统实现滤棒长度的在线检测,检测精度为0.01mm;系统运行稳定可靠,操作简单易懂,人机交互性较好,对提高滤棒长度的在线监控水平、自动化程度和滤棒质量具有较好的实用价值。

隔离开关合闸状态的非接触自动检测方法

为了提升隔离开关合闸状态自动检测效果,采用了基于激光位移传感器的隔离开关合闸状态非接触自动检测方法,使激光位移传感器的分辨率达到最大值,优化了激光位移传感器的光学参数,提升了其位移测量精度;通过光学参数优化后的激光位移传感器,采集隔离开关轮廓曲线,得到隔离开关轮廓曲线采样点集;利用最小二乘法拟合隔离开关轮廓曲线采样点的椭圆方程,并计算隔离开关导电臂与水平方向的夹角;当导电臂夹角处于规定夹角区间内,则判定合理开关合闸到位,完成隔离开关合闸状态非接触自动检测。结果表明,该方法计算的前、后导电臂夹角分别在0.4°与0.5°左右,均低于夹角规定区间。这一结果对实现隔离开关合闸状态非接触自动检测是有帮助的。

激光位移传感器动态幅值校准研究

针对目前激光位移传感器校准所存在的精度低、校准局限性大等诸多问题,本文提出了一种激光位移传感器动态幅值校准的方法。本校准方法首先采用电磁振动台激励标准结构件进行量级放大,以产生特定高频的大位移振幅;然后基于多普勒效应的激光测振仪测得的位移作为标准量,对激光位移传感器的动态幅值进行校准;最后通过一系列不同共振频率的标准结构件对不同频率下的位移振幅校准进行试验研究。研究结果表明:与现有技术相比较,本文提出的激光位移传感器动态幅值校准方法可对激光位移传感器不同频率下的动态幅值进行精确校准,对工程实际应用具有重要价值。

优化非线性误差的激光位移传感器测距仿真

激光位移传感器需要具有高精度和高分辨率的测量能力,以满足实际应用的需求,为此提出一种优化非线性误差的激光位移传感器测距方法。在物联网环境下,通过双目视觉系统得到激光位移传感器光束的光斑位置,采用最小二乘法拟合光束直线得到光束方向参数,同时利用激光位移传感器的数值求解零点位置,实现距离测量。由于测距过程中存在非线性固有误差,为此引入BP神经网络对激光位移传感器的测距误差展开训练,完成位移误差补偿。仿真结果表明,所提方法可以有效降低激光位移传感器测距误差,同时还可以有效缩短测距耗时。

基于激光位移传感器的预对准方法分析

阐述设计的一种基于高精度激光位移传感器实现预对准的方法,并分析晶圆边缘扫描特征对晶圆圆心定位精度误差的主要影响因素。为进一步探究原因,同时测试工件台水平度、采样频率和扫描路径对晶圆扫描结果的影响,验证了使用激光位移传感器实现激光退火前预对准的有效性、稳定性。

基于激光位移传感器的可视化表面粗糙度测量系统

表面粗糙度是表面微观几何形状误差,它是评价材料加工质量的一个重要参量。传统接触式测量表面粗糙度容易造成表面划伤,且测量速度低,不适合在线测量,而非接触式测量方法能够克服上述不足。本文设计了一种基于激光位移传感器的非接触式表面粗糙度测量系统,对设定区域扫描,实现对物体表面微观变化的在线检测,通过分析反射光强的变化,获得物体表面形貌变化及偏差信息。该系统采用MP340单片机进行数据处理,借助可视化人机交互界面实时监测被测物体表面状态结果。实验测试表明,系统原理直观,测试数据精确可靠,抗背景光干扰能力强,轴向检测范围在1~80µm的测量,精度小于5µm,为实际应用提供一种技术参考。

Optical feedback characteristics in a dual-frequency laser during laser cavity tuning

The optical feedback characteristics in a Zeeman-birefringence dual-frequency laser are studied during the laser cavity tuning in three different kinds of optical feedback conditions： （i） only //-light is fed back; （ii） only ⊥-light is fed back; （iii） both lights are fed back. A compact displacement sensor is designed using the experimental result that there is a nearly 90 degrees phase delay between the two lights＇ cosine optical feedback signals when both lights are fed back into the laser cavity. The priority order that the two lights＇ intensity curves appear can be used for direction discrimination. The resolution of the displacement sensor is at least 79 rim, and the sensor can discriminate the target＇s moving direction easily.

Extrinsic calibration of a laser displacement sensor in a non-contact coordinate measuring machine

In order to implement 3D scanning of those complicated parts such as blades in the aviation field,a non-contact optical measuring system is established in the paper,which integrates a laser displacement sensor,a probe head,the frame of a coordinate measuring machine（CMM）,etc.As the output of the laser sensor directly obtained possesses the 1D length of the laser beam,it needs to determine the unit direction vector of the laser beam denoted as（l,m,n）by calibration so as to convert the 1D values into 3D coordinates of target points.Therefore,an extrinsic calibration method based on a standard sphere is proposed to accomplish this task in the paper.During the calibration procedure,the laser sensor moves along with the motion of the CMM and gathers the required data on the spherical surface.Then,both the output of the laser sensor and the grating readings of the CMM are substituted into the constraint equation of the spherical surface,in which an over-determined nonlinear equation group containing unknown parameters is established.For the purpose of solving the equation group,a method based on non-linear least squares optimization is put forward.Finally,the system after calibration is utilized to measure the diameter of a metallic sphere 10 times from different orientations to verify the calibration accuracy.In the experiment,the errors between the measured results and the true values are all smaller than 0.03 mm,which manifests the validity and practicality of the extrinsic calibration method presented in the paper.

Calibration of laser beam direction based on monocular vision

In the laser displacement sensors measurement system,the laser beam direction is an important parameter.Particularly,the azimuth and pitch angles are the most important parameters to a laser beam.In this paper,based on monocular vision,a laser beam direction measurement method is proposed.First,place the charge coupled device(CCD)camera above the base plane,and adjust and fix the camera position so that the optical axis is nearly perpendicular to the base plane.The monocular vision localization model is established by using circular aperture calibration board.Then the laser beam generating device is placed and maintained on the base plane at fixed position.At the same time a special target block is placed on the base plane so that the laser beam can project to the special target and form a laser spot.The CCD camera placed above the base plane can acquire the laser spot and the image of the target block clearly,so the two-dimensional(2D)image coordinate of the centroid of the laser spot can be extracted by correlation algorithm.The target is moved at an equal distance along the laser beam direction,and the spots and target images of each moving under the current position are collected by the CCD camera.By using the relevant transformation formula and combining the intrinsic parameters of the target block,the2D coordinates of the gravity center of the spot are converted to the three-dimensional(3D)coordinate in the base plane.Because of the moving of the target,the3D coordinates of the gravity center of the laser spot at different positions are obtained,and these3D coordinates are synthesized into a space straight line to represent the laser beam to be measured.In the experiment,the target parameters are measured by high-precision instruments,and the calibration parameters of the camera are calibrated by a high-precision calibration board to establish the corresponding positioning model.The measurement accuracy is mainly guaranteed by the monocular vision positioning accuracy and the gravity center extraction accuracy.The experimental results show the maximum error of the angle between laser beams reaches to0.04°and the maximum error of beam pitch angle reaches to0.02°.

Fiber-Optic Displacement Sensor Based on the DBR Fiber Laser

The fiber-optic displacement sensor based on the distributed Bragg reflector fiber laser is proposed, that is, the fiber laser cavity is attached to the measured object, when the measured object is stretched or contracted, and the length of the fiber laser cavity is also stretched or contracted accordingly. In view of the nonlinearity of the fiber-optic displacement sensor, the calibration based on piezoelectric ceramics is applied to improve the linearity of the displacement sensor. Experiment results show that the fiber-optic displacement sensor has a linear response with the nominal working distance of 90 um.

基于激光位移法的电梯曳引轮轮槽磨损量检测方法研究

本文开发了一种基于激光位移法的曳引轮轮槽磨损检测装置;设计的专用夹具使激光传感器置于曳引轮下方,避免钢丝绳遮挡,实现轮槽磨损在线检测;线激光传感器提取曳引轮各轮槽轮廓坐标值,对不同位置轮槽轮廓曲线线性拟合,计算出轮廓曲线斜率、轮槽节圆圆心、轮槽磨损量和轮槽角,根据规范对曳引能力进行评价;检测装置的最大均方根误差为0.062 mm,满足曳引轮轮槽检测的精度要求。

激光位移传感器的零部件表面损伤非接触检测研究

激光位移传感器存在定位误差,导致零部件表面损伤检测准确率较差,为此设计了激光位移传感器的零部件表面损伤非接触检测方法。利用调平机构垂直于零部件安装激光位移传感器采集零部件图像,并通过传感器中CCD相机标定图像坐标,通过坐标变换来校正图像坐标中的轮廓线畸变,利用实际零部件轮廓坐标与校正后的轮廓坐标相融合,获得零部件的轮廓区域,作为零部件表面损伤检测的背景区域图像,利用最大熵阈值分割算法自动二值化该背景区域图像,使用梯度算法获取二值化背景区域图像中发生突变的灰度值边缘或者点,再进行增长区域,直至检测出零部件表面损伤面积。试验结果显示,该检测方法能够检测出零部件表面的点蚀、擦伤、剥离、裂纹等损伤情况,检测准确率较高,检测误差更小。