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.

Laser Deposition of Tetrasulfonated Phthalocyanine Layers for Gas Sensors

Thin layers of nickel and copper tetrasulfonated phthalocyanines (NiPcTS and CuPcTS) were prepared by Matrix Assisted Pulsed Laser Evaporation method. The depositions were carried out with KrF excimer laser (energy density of laser radiation EL = 0.1 to 0.5 J.cm-2) from dimethylsulfoxide matrix. For both materials the ablation threshold EL-th was determined. The following properties of deposited layers were characterized: a) chemical composition (FTIR spectra);b) morphology (SEM and AFM portraits);c) impedance of gas sensors based on NiPcTS and CuPcTS layers in the presence of two analytes - hydrogen and ozone. The prepared sensors exhibit response to 1000 ppm of hydrogen and 100 ppb of ozone even at laboratory temperature.

Random Raman Fiber Laser as a Liquid Refractive Index Sensor

In this paper,a new concept of forward-pumped random Raman fiber laser(RRFL)-based liquid refractive index sensing is proposed for the first time.For liquid refractive index sensing,the flat fiber end immersed in the liquid can act as the point reflector for generating random fiber lasing and also as the sensing head.Due to the high sensitivity of the output power of the RRFL to the reflectivity provided by the point reflector in the ultralow reflectivity regime,the proposed RRFL is capable of achieving liquid refractive index sensing by measuring the random lasing output power.We theoretically investigate the effects of the operating pump power and fiber length on the refractive index sensitivity for the proposed RRFL.As a proof-of-concept demonstration,we experimentally realize high-sensitivity half-open short-cavity RRFL-based liquid refractive index sensing with the maximum sensitivity and the sensing resolution of-39.88W/RIU and 2.5075×10^(-5) RIU,respectively.We also experimentally verify that the refractive index sensitivity can be enhanced with the shorter fiber length of the RRFL.This work extends the application of the random fiber laser as a new platform for highly-sensitive refractive index sensing in chemical,biomedical,and environmental monitoring applications,etc.

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。

基于IMU与激光雷达融合的无人弹药补给车SLAM系统研究

针对单一传感器建图精度低、实时性不足的问题,将IMU融合到激光雷达SLAM算法中。首先,采用手眼标定方法对2种传感器坐标系外参进行标定,实现传感器在时间与空间上的对齐。然后,结合因子图优化模型,解决在建图过程中产生的漂移现象,并将IMU融合到激光雷达LeGO-LOAM算法中。最后,在室外场景下搭建了无人弹药补给车SLAM实验平台,分别进行了LeGO-LOAM算法融合IMU前后的建图和定位试验。结果表明,融合IMU后的SLAM算法建图和定位精度都明显提高,满足了在未知环境下无人弹药补给车建图和定位的性能要求。

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。

基于精密激光测距技术的旋翼桨毂离心试验台限位行程传感器校准方法研究

论述了用于旋翼桨毂大修装配调试阶段承担模拟旋翼桨毂在低、高转速状态下,离心限动块打开和复位试验的离心试验台的工作原理,确定了旋翼桨毂多次打开、复位试验仍不满足工艺要求的原因为离心试验台限位行程测量不准,致使离心限动块打开和复位试验出现误判,最终影响装备的修理质量和进度。针对此问题,提出了一种基于精密激光测距技术的离心试验台限位行程传感器的校准方法,可实现离心试验台限位行程传感器的精准计量,测量精度达±1μm,测量不确定度为0.006μm+1.92×10^(-5)L。

基于十字交叉激光法的机器人TCP校准系统开发

在工业机器人应用于弧焊、点焊、涂胶等接触任务过程中,为实现工具中心点(TCP)位姿误差高效校准,提出基于U形激光测量传感器的TCP非接触式测量系统。该系统采用十字交叉激光法进行误差模型测量和更新末端工具坐标,实现机器人预设运行轨迹的自动修正,克服了离线编程中因工具坐标系发生偏移而导致的焊接质量的不确定性。系统通过TCP校准程序测量TCP与机器人末端法兰中心的相对位置,校准结果重复精度优于0.6077 mm,验证测量结果的准确性和运动轨迹精度。

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。

Time Series-, Time-Frequency- and Spectral Analyses of Sensor Measurements in an Offshore Wave Energy Converter Based on Linear Generator Technology

Inside the second experimental wave energy converter (WEC) launched at the Lysekil research site on the Swedish west coast in March 2009 a number of sensor systems were installed for measuring the mechanical performance of the WEC and its mechanical subsystems. One of the measurement systems was a set-up of 7 laser triangulation sensors for measuring relative displacement of the piston rod mechanical lead-through transmission in the direct drive. Two measurement periods, separated by 2.5 month, are presented in this paper. One measurement is made two weeks after launch and another 3 months after launch. Comparisons and correlations are made between different sensors measuring simultaneously. Noise levels are investigated. Filtering is discussed for further refinement of the laser triangulation sensor signals in order to separate noise from actual physical displacement and vibration. Measurements are presented from the relative displacement of the piston rod mechanical lead-through, from magnetic flux in the air gap, mechanical strain in the WEC structure, translator position and piston rod axial displacement and active AC power. Investigation into the measurements in the time domain with close-ups, in the frequency domain with Fast Fourier transform (FFT) and with time-frequency analysis with short time Fourier transform (STFT) is carried out to map the spectral content in the measurements. End stop impact is clearly visible in the time-frequency analysis. The FFT magnitude spectra are investigated for identifying the cogging bandwidth among other vibrations. Generator cogging, fluctuations in the damping force and in the Lorenz forces in the stator are distinguished and varies depending on translator speed. Vibrations from cogging seem to be present in the early measurement period while not so prominent in the late measurement period. Vibration frequencies due to wear are recognized by comparing with the noise at generator standstill and the vibration sources in the generator. It is concluded that a moving average is a sufficient filter in the time domain for further analysis of the relative displacement of the piston rod mechanical lead-through transmission.

ASSESSING THE DYNAMIC ERRORS OF COORDINATE MEASURING MACHINES

The main factors affecting the dynamic errors of coordinate measuring machines are analyzed. It is pointed out that there are two main contributors to the dynamic errors: One is the rotation of the elements around the joints connected with air bearings and the other is the bending of the elements caused by the dynamic inertial forces. A method for obtaining the displacement errors at the probe position from dynamic rotational errors is presented. The dynamic rotational errors are measured with inductive position sensors and a laser interferometer. The theoretical and experimental results both show that during the process of fast probing, due to the dynamic inertial forces, there are not only large rotation of the elements around the joints connected with air bearings but also large bending of the weak elements themselves.

消多普勒饱和吸收激光稳频教学实验平台

激光器是原子磁强计、原子陀螺仪等量子传感器的核心部件。量子传感器通过激光、磁场等与原子的相互作用,实现对相应物理量的高精度测量。激光频率优化及稳定是实现量子精密测量的关键技术。该文在理解原子能级跃迁、激光饱和吸收稳频原理基础上,搭建了消多普勒激光饱和吸收稳频教学实验平台,通过扫描铷原子的消多普勒饱和吸收光谱,将激光频率锁定在铷原子的D1线上,获得了频率高度稳定的激光输出。该平台能够使学生直接观测原子吸收与激光频率稳定的过程,有助于学生对激光与原子相互作用的深入理解以及实验动手能力的提升,为研究生和本科生的相关课程教学提供了有力支撑。

基于逐层切割法不规则果实体积测量的研究

研究一种不规则果实体积综合测量装置,实现对果实的体积、纵径、横径、表面粗糙度等相关指标的一次性测量。采用丝杆机构双向移动实现果实自动定位,解决不规则水果中心难以确定问题;设计自带径向移动的旋转机构,满足不同大小果径测量;基于不规则曲面立体切割法实时测算果实体积,测量精度高,一次装夹可以实现多个参数指标的测量。实验结果显示:测量直径为175 mm的规则物(球),横径误差为0.39%,体积误差为0.32%,以不规则物为试件(最大横径为104 mm),横径误差为0.16%,体积误差为0.17%,具有较高的精度,并且果径越小,精度越高。该装置的应用可降低果实分拣的劳动强度,满足科学研究的需求,为准确快速地测量不规则物体积提供了一种新的思路。

基于2D位移激光传感器的钢轨波磨动态检测方法

针对2D位移激光传感器在高速和宽波段的钢轨波磨动态测量过程中受到点头振动和噪声干扰的问题,提出一种基于经验模态分解(EMD)的分趋势式数据拼接方法。首先,将采集到的波磨数据进行EMD,并将其分为长趋势与短趋势;然后,通过盲识别方法提取出数据采集中产生的偏移角度,从而准确提取出相邻采样数据之间的相干数据集;最后,通过不同趋势段的数据配准完成相邻采样数据集的拼接。实验结果表明:所提方法可稳定、精确地在真实铁路测量环境中对钢轨波磨进行测量。

基于立体视觉的IGBT针高检测

针对现有绝缘栅双极晶体管(IGBT)的pin针高度测量系统不能稳定、可靠地测量pin针高度的问题,设计了一套基于双线激光传感器的pin针高度测量系统。双线激光传感器采用上下错高的安装布局,分别采集IGBT针尖部分和底面部分的点云数据。同时,基于双线激光传感器采集的点云数据开发了一套测量pin针高度的测量程序。分别使用随机抽样一致性(RANSAC)算法处理基准面点集的离群点,使用多步去噪算法处理精确点集。实验结果表明,该系统的测量重复度小于0.04 mm,且极差分布在(0.021 mm,0.039 mm)的概率超过99.7%,有着良好的稳定性和可靠性。

一种基于卡尔曼滤波的自由曲面扫描测量方法

将激光位移传感器安装在旋转的机构上实现对自由曲面的内径测量,创新提出了一种基于卡尔曼滤波的高精度补偿算法,有效解决了异形面的激光高精度测量难题。首先介绍分析了激光三角法的测量原理,结合被测对象的结构特点,设计了一种仿形测量方法,采用几何定心的原理,对自由曲面的弧面半径进行高精度的离散测量。建立了标准卡尔曼滤波算法,蒙特卡洛方法用于模拟激光位移传感器测量的半径范围结果,对模拟的范围结果提出运用卡尔曼滤波技术进行误差补偿,并在MATLAB上进行实验仿真,最后对仿真结果进行分析。实验结果表明,该方法能够将数据的标准差降低近50%,并过滤掉明显噪点。该测量方法能应用在不同半径范围的管道自由曲面,有效减小了测量过程中产生的误差,提高了测量精度,为提高管道内径测量精度提供了参考。

基于MG-Y激光器的光纤法珀传感器信号处理系统

针对目前光纤法珀传感器腔长解调系统复杂的问题,提出了一种以MG-Y可调谐激光器为扫描光源的光纤法珀传感器信号处理系统。该系统利用FPGA主控芯片驱动MG-Y激光器实现C波段的线性扫描,同时将光谱信号以触发采样的方式转化为电学信号传送到上位机,设计LabVIEW上位机实现傅里叶频率测量法与最小二乘拟合法运算,最终完成传感器腔长的解调。在实验中使用该系统对不同腔长的光纤法珀传感器进行解调运算,并将解调结果与光谱分析仪解调结果进行对比,实验表明二者具有较好的一致性,在不损失精度的情况下实现了解调系统的小型化。

加速度传感器对重力仪振动补偿效果分析

为分析加速度传感器对重力仪的补偿效果,基于NIM-3C绝对重力仪搭建了平台式重力测量实验平台,并用激光测振仪输出信号作为标准信号,通过实验标定了平台式重力测量环境下MSA1000A-02、991B、INV9832-50三种不同型号的加速度型传感器的振动采集性能。实验结果表明,为保证平台式重力测量环境下的重力测量不确定度达到mGal量级,加速度计引入的测量不确定度应在百μGal以内。在平台式重力测量工况下,传感器MSA1000A-02和激光测振仪所测振动(标准信号)的拟合二次项系数极差为2.94μGal,满足平台式重力测量环境的不确定度及带宽等的要求。

非接触三点内径测量法中角度安装误差的校准方法研究

由于操作简便,非接触三点内径测量法常用于工业现场测量。为提高工件内径测量精度,对在安装中无法避免的位移传感器角度安装误差进行分析建模,提出了一个新的考虑角度安装误差的非接触内径测量模型及一种基于多观测位置联立方程的误差校准方法。通过仿真分析了模型中观测位置数、工件内径尺寸与其他参数的设置对校准结果的影响,确认了在观测位置数大于4时即可实现对误差的校准。最终,使用激光位移传感器构建内径测量系统并开展实验,验证了角度安装误差校准方法的有效性,圆工件的内径测量的绝对精度与重复性精度分别在0.6μm与0.4μm以下。