Surface form inspection with contact coordinate measurement:a review

Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with coordinate measuring machines or computer numerical control machine tool is a fundamental technique due to its high accuracy,robustness,and universality.In this paper,the existing research in the contact measurement field is systematically reviewed.First,different configurations of the measuring machines are introduced in detail,which may have influence on the corresponding sampling and inspection path generation criteria.Then,the entire inspection pipeline is divided into two stages,namely the pre-inspection and post-inspection stages.The typical methods of each sub-stage are systematically overviewed and classified,including sampling,accessibility analysis,inspection path generation,probe tip radius compensation,surface reconstruction,and uncertainty analysis.Apart from those classical research,the applications of the emerging deep learning technique in some specific tasks of measurement are introduced.Furthermore,some potential and promising trends are provided for future investigation.

ANALYSIS AND MEASUREMENT FOR THE DYNAMIC ERRORS OF COORDINATE MEASURING MACHINES

The analysis and calculating method of dynamic errors of CMMs during probing are discussed.To relate the dynamic displacement errors with the dynamic rotational errors a method for obtaining the displacement errors at the probing position from dynamic rotational errors is presented.It is pointed out that the finite element method might be used for modeling dynamic errors.However,dynamic errors are difficult to be modeled so a combined practical and theoretical approach is needed.In addition,the dynamic errors are measured with inductive position sensors.

STUDY OF NON-CONTACT MEASUREMENT OF FREE-FORM SURFACES

A non contact three dimensional measurement method is presented in this paper.This system consists of a laser triangulation probe,a probe head and a coordinate measuring machine (CMM).The measurement principle of the system is discussed,and a system calibration method employing a reference ball is proposed.The geometric model involving four frames is established to calculate the data points based on the reading of the laser probe and position information from the CMM.A measuring experiment for gesso free form surface using this system is carried out.

METHODS OF VISUAL RECOGNITION,POSITIONING AND ORIENTATING OF 3 D SIMPLE GEOMETRIC WORKPIECE

The methods of visual recognition,positioning and orienting with simple 3 D geometric workpieces are presented in this paper.The principle and operating process of multiple orientation run length coding based on general orientation run length coding and visual recognition method are described elaborately.The method of positioning and orientating based on the moment of inertia of the workpiece binary image is stated also.It has been applied in a research on flexible automatic coordinate measuring system formed by integrating computer aided design,computer vision and computer aided inspection planning,with a coordinate measuring machine.The results show that integrating computer vision with measurement system is a feasible and effective approach to improve their flexibility and automation.

Novel Method for Spatial Angle Measurement Based on Rotating Planar Laser Beams

Spatial angle measurement, especially the measurement of horizontal and vertical angle, is a basic method used for industrial large-scale coordinate measurement. As main equipments in use, both theodolites and laser trackers can provide very high accuracy for spatial angle measurement. However, their industrial applications are limited by low level of automation and poor parallelism. For the purpose of improving measurement efficiency, a lot of studies have been conducted and several alternative methods have been proposed. Unfortunately, all these means are either low precision or too expensive. In this paper, a novel method of spatial angle measurement based on two rotating planar laser beams is proposed and demonstrated. Photoelectric receivers placed on measured points are used to receive the rotating planner laser signals transmitted by laser transmitters. The scanning time intervals of laser planes were measured, and then measured point＇s horizontal/vertical angles can be calculated. Laser plane＇s angle parameters are utilized to establish the abstract geometric model of transmitter. Calculating formulas of receiver＇s horizontal/vertical angles have been derived. Measurement equations＇ solvability conditions and judgment method of imaginary solutions are also presented after analyzing. Proposed method for spatial angle measurement is experimentally verified through a platform consisting of one laser transmitter and one optical receiver. The transmitters used in new method are only responsible for providing rotating light plane signals carrying angle information. Receivers automatically measure scanning time of laser planes and upload data to the workstation to calculate horizontal angle and vertical angle. Simultaneous measurement of multiple receivers can be realized since there is no human intervention in measurement process .Spatial angle measurement result indicates that the repeatable accuracy of new method is better than 10＂. Proposed method can improve measurement＇s automation degree and speed while ensuring measurement accuracy.

CAD Model-Based Intelligent Inspection Planning for Coordinate Measuring Machines

As the market competition among enterprises grows intensively and the demand for high quality products increases rapidly, product quality inspection and control has become one of the most important issues of manufacturing, and improving the efficiency and accuracy of inspection is also one of problems which enterprises must solve. It is particularly important to establish rational inspection planning for parts before inspecting product quality correctly. The traditional inspection methods have been difficult to satisfy the requirements on the speed and accuracy of modern manufacturing, so CAD-based computer-aided inspection planning （CAIP） system with the coordinate measuring machines （CMM） came into being. In this paper, an algorithm for adaptive sampling and collision-free inspection path generation is proposed, aiming at the CAD model-based inspection planning for coordinate measuring machines （CMM）. Firstly, using the method of step adaptive subdivision and iteration , the sampling points for the specified number with even distribution will be generated automatically. Then, it generates the initial path by planning the inspection sequence of measurement points according to the values of each point＇s weight sum of parameters, and detects collision by constructing section lines between the probe swept-volume surfaces and the part surfaces, with axis-aligned bounding box （AABB） filtering to improve the detection efficiency. For collided path segments, it implements collision avoidance firstly aiming at the possible outer-circle features, and then at other collisions, for which the obstacle-avoiding movements are planned with the heuristic rules, and combined with a designed expanded AABB to set the obstacle-avoiding points. The computer experimental results show that the presented algorithm can plan sampling points＇ locations with strong adaptability for different complexity of general surfaces, and generate efficient optimum path in a short time and avoid collision effectively.

Multiple Measurement Models of Articulated Arm Coordinate Measuring Machines

The existing articulated arm coordinate measuring machines（AACMM） with one measurement model are easy to cause low measurement accuracy because the whole sampling space is much bigger than the result in the unstable calibration parameters. To compensate for the deficiency of one measurement model, the multiple measurement models are built by the Denavit-Hartenberg＇s notation, the homemade standard rod components are used as a calibration tool and the Levenberg-Marquardt calibration algorithm is applied to solve the structural parameters in the measurement models. During the tests of multiple measurement models, the sample areas are selected in two situations. It is found that the measurement errors＇ sigma value（0.083 4 ram） dealt with one measurement model is nearly two times larger than that of the multiple measurement models（0.043 1 ram） in the same sample area. While in the different sample area, the measurement errors＇ sigma value（0.054 0 ram） dealt with the multiple measurement models is about 40% of one measurement model（0.137 3 mm）. The preliminary results suggest that the measurement accuracy of AACMM dealt with multiple measurement models is superior to the accuracy of the existing machine with one measurement model. This paper proposes the multiple measurement models to improve the measurement accuracy of AACMM without increasing any hardware cost.

Single Camera 3-D Coordinate Measuring System Based on Optical Probe Imaging

A new vision coordinate measuring system--single camera 3 D coordinate measuring system based on optical probe imaging is presented. A new idea in vision coordinate measurement is proposed. A linear model is deduced which can distinguish six freedom degrees of optical probe to realize coordinate measurement of the object surface. The effects of some factors on the resolution of the system are analyzed. The simulating experiments have shown that the system model is available.

Flexible Scanning Method by Integrating Laser Line Sensors with Articulated Arm Coordinate Measuring Machines

Measuring and reconstructing the shape of workpieces have been considered as a fundamental step in both reverse engineering and product quality control.Owing to increasing structural complexity of recent products,measurements from multiple directions are typically required in current scanning techniques.Specifically,the plane structured light can be applied to measure one area of a part at a time,with an additional algorithm required to merge the collected data of each area.Alternatively,the line structured light sensor integrated on CNC machines or CMMs could also realize multi-view measurement.However,the system needs to be repeatedly calibrated at each new direction.This paper presents a flexible scanning method by integrating laser line sensors with articulated arm coordinate measuring machines(AACMM).Since the output of the laser line sensor is 2D raw data in the laser plane,our system model introduces an explicit transformation from the 2D sensor coordinate frame to the 3D base coordinate frame of the AACMM(i.e.,the translation and rotation the of the 2D sensor coordinate in the sixth coordinate system of AACMM).To solve the model,the“conjugate pairs”are proposed and identified by measuring a fixed point(e.g.,a sphere center).Moreover,a search algorithm is adopted to find the optimal solution,which noticeably boosts the model accuracy.The experimental results show that the error of the system is about 0.2 mm,which is caused by the error of the AACMM,the sensor error and the calibration error.By measuring a complicated part,the proposed system is proved to be flexible and facilitate,with the ability to measure a part expediently from any necessary direction.Furthermore,the proposed calibration method can also be used for robot hand-eye relationship calibration.

Dynamic Coordination of Uncalibrated Hand/Eye Robotic System Based on Neural Network

A nonlinear visual mapping model is presented to replace the image Jacobian relation for uncalibrated hand/eye coordination. A new visual tracking controller based on artificial neural network is designed. Simulation results show that this method can drive the static tracking error to zero quickly and keep good robustness and adaptability at the same time. In addition, the algorithm is very easy to be implemented with low computational complexity.

Development of an in-situ measuring system for blisk manufacturing

In order to solve the in-situ measurement problem of workpiece with complex structures,a cantilever coordinate measuring machine(CCMM)is proposed to adapt to the finite space constraints of the 5-axis computer numerical control(CNC)processing site.Structure design of dense ball bearing shafting is analyzed and optimized.Factors affecting measurement accuracy of CCMM are analyzed,and measurement accuracy is validated by experiments.Results show that the structure of CCMM is able to satisfy requirements of technical specification,and the in-situ measurement of blisk manufacturing is realized.The CCMM developed is of important significance for machining quantity improvement of blisk and development of large aircraft production.

ERROR COMPENSATION OF COORDINATE MEASURING MACHINES WITH LOW STIFFNESS

A technique for compensating the errors of coordinate measuring machines (CMMs) with low stiffness is proposed. Some additional items related with the force deformation are introduced to the error compensation aquations. The research was carried on a moving colunm horizontal arm CMM. Experimental results show that both the effects of systematic components of error motions and force deformations are greatly reduced, which shows the effectiveness of proposed technique.

Robot Vision System for Coordinate Measurement of Feature Points on Large Scale Automobile Part

In this paper,we present a robot vision based system for coordinate measurement of feature points on large scale automobile parts.Our system consists of an industrial 6-DOF robot mounted with a CCD camera and a PC.The system controls the robot into the area of feature points.The images of measuring feature points are acquired by the camera mounted on the robot.3D positions of the feature points are obtained from a model based pose estimation that applies to the images.The measured positions of all feature points are then transformed to the reference coordinate of feature points whose positions are obtained from the coordinate measuring machine（CMM）.Finally,the point-to-point distances between the measured feature points and the reference feature points are calculated and reported.The results show that the root mean square error（RMSE） of measure values obtained by our system is less than 0.5 mm.Our system is adequate for automobile assembly and can perform faster than conventional methods.

COORDINATE MEASURING MACHINE PROBING ACCESSIBILITY

The accessibility of coordinate measuring machines (CMMs) in dimensional inspection is studied. The problem of computing the global accessibility cone is solved using a method of angle representation. Otherwise, the length and volume of probe are considered sufficiently so that all the feasible probe orientations could be determined for the inspection of a workpiece when a touch trigger probe is used and the shortcoming of abstracting a probe as an infinite half line could be overcome completely. In the end, an example is given to explain the method.

GUIDELESS SPATIAL COORDINATE MEASUREMENT TECHNOLOGY BASED ON CODING POLE

A new method of guideless spatial coordinate measurement technology based on coding pole and vision measurement is proposed. Unequal spacing of bar code is adopted to pole, so that the code combination of pole image in measuring field is unique. Holographic characteristics of numeric coding pole are adopted to obtain pole pose and pole probe position by any section of bar code on the pole. Spatial coordinates of measuring points can be obtained by coordinate transform. The contradiction between high resolution and large visual field of image sensor is resolved, thereby providing a new concept for surface shape measurement of large objects with high precision. The measurement principles of the system are expounded and mathematic model is established. The measurement equation is evaluated by simulation experiments and the measurement precision is analyzed. Theoretical analysis and simulation experiments prove that this system is characterized by simple structure and wide measurement range. Therefore it can be used in the 3-dimentional coordinate measurement of large objects.

Determination of the workspace of a new coordinate-measuring machine using parallel-link mechanism

Presents the detailed algorithm established for determination of workspace for a 3-DOF coordinate measuring machine using parallel link mechanism by constructing the inverse kinematic model first and then reviewing the physical and kinematical constraints from the structural characteristics of the parallel link mechanism, and discusses the actual geometries of workspace and the factors having effect on workspace through computer simulation thereby providing necessary theoretical basis for the research and development of coordinate measuring machines using parallel link mechanism.

Cylindrical coordinate measuring machines: probe offset and workpiece clamping error

A cylindrical coordinate measuring machine for the detection of large-size rotational parts is introduced. The measuring machine can simultaneously measure the geometrical dimensions, form and position errors of the inner and outer surfaces. Since the maximum length of the workpiece can reach 2 000 mm , it is difficult to be clamped and adjusted and easy to produce clamping error. The eccentricity can be up to 1.5 mm, which has an interaction effect with the probe mounting offset. We mainly study the probe offset of the measuring machine and the influence of the workpiece clamping error on the measurement. A method of controlling the offset of the measuring probe is proposed. The effect of the clamping error is eliminated through the space coordinate transformation of the workpiece axis, and the axis is fitted by the least square method. Finally, a common fixture can be realized to meet the clamping requirements of the workpiece.

Light pen whole space coordinate measuring system based on a tracking turntable

Light pen coordinate measuring system(LPCMS)is a kind of portable coordinate measuring technique based on vision metrology.In classical LPCMS,the measuring range is limited to the camera’s field of view.To overcome this defect,a new LPCMS is designed in this paper to fulfil whole space coordinate measurement.The camera is installed on a turntable instead of a tripod,so that the camera can rotate to track the movement of the light pen.The new system can be applied to large scale onsite measurement,and therefore it notably extends the application of LPCMS.To guarantee the accuracy of the new system,a method to calibrate the parameters of the tracking turntable is also proposed.Fixing the light pen at a stationary position,and changing the azimuth angles of the turntable’s two shafts,so that the camera can capture the images of the light pen from different view angles.According to the invariant spatial relationship between the camera and the pedestal of the tracking turntable,a system of nonlinear equations can be established to solve the parameters of the turntable.Experimental results show that the whole space coordinate measuring accuracy of the new system can reach 0.25 mm within 10 m.It can be concluded that the newly designed system can significantly expand the measuring range of LPCMS without losing too much accuracy.

The definition analyses of radiation temperature measurement area

In the research of primary spectrum pyrometry, this paper discussed the definition problem of radiation temperature measurement area based on the measurement coordinates. For the linear spectrum emissivity model and improved monotonic spectrum emissivity model, the characteristics of radiation temperature measurement area restricted by the measurement coordinates were theoretically analyzed, through the investigations of the temperature and emissivity coordinate axes. Choosing the specific primary spectrum pyrometer as an example in applications, the theoretical area of radiation temperature measurement of this pyrometer was given and it was verified through blackbody experiments. The discussions of this paper will provide the necessary foundation for the theory research development of primary spectrum pyrometry and the realization of technical applications.

Theoretical analysis and verification of uncertainty of measurement on a cantilever coordinate measuring machine

A cantilever coordinate measuring machine(CCMM)is proposed according to the in-situ measurement requirement of workpieces with complex structures limited by the finite space of the5-axes computerized numerical control(CNC)processing site.Factors affecting uncertainty of measurement(UM)are classified and analyzed on the basis of uncertainty evaluation criteria,and the estimation technique of UM for measuring systems is presented.UM of the CCMM is estimated from the factors such as temperature,error motions as well as the mechanism deformations.Measurement results show that the actual measurement error is smaller than that of measurement requirement.