Measurement and Compensation of Deviations of Real Tooth Surface of Spiral Bevel Gear

This paper presents a method for measurement of deviation of the real gear tooth surface from the theoretical one with a coordinate measurement machine and compensation of repeatable parts. By investigation of characteristics of distortion of the gear tooth surface along the circle direction, the deviation is derived from distortion, and the definition of deviation with the geometrical invariability is proposed. Then the approach for determination of the location and orientation of the gear with respect to the coordinate measurement machine and the measurement way are developed. The deviation is represented with a difference surface, and an algorithm for derivation of parameters of global form deviations from the discrete points has been provided. Finally, the compensation approach is discussed.

Self-calibration and Compensation of Setting Errors for Surface Profile Measurement of a Microstructured Roll Workpiece

Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll workpieces, and types of measurement systems and measurement methods have been developed. However, low measurement efficiency and low measurement accuracy caused by setting errors are the common disadvantages for surface profile measurement of microstructured roll workpieces. In order to shorten the measurement time and enhance the measurement accuracy, a method for self-calibration and compensation of setting errors is proposed for surface profile measurement of microstructured roll workpieces. A measurement system is constructed for the measurement, in which a precision spindle is employed to rotate the roll workpiece and an air-bearing displacement sensor with a micro-stylus probe is employed to scan the microstructured surface of the roll workpiece. The resolution of the displacement sensor is 0.14 nm and that of the rotary encoder of the spindle was 0.15r~. Geometrical and mathematical models are established for analyzing the influences of the setting errors of the roll workpiece and the displacement sensor with respect to the axis of the spindle, including the eccentric error of the roll workpiece, the offset error of the sensor axis and the zero point error of the sensor output. Measurement experiments are carded out on a roll workpiece on which periodic microstructures are a period of 133 i^m along the circumferential direction. Experimental results demonstrate the feasibility of the self-compensation method. The proposed method can be used to detect and compensate the setting errors without using any additional accurate artifact.

The Approach of Compensation of Air Refractive Index in Thermal Expansion Coefficients Measurement Based on Laser Feedback Interferometry

We present the thermal expansion coefficient （TEC） measurement technology of compensating for the effect of variations in the refractive index based on a Nd： YA G laser feedback system, the beam frequency is shifted by a pair of aeousto-optic modulators and then the heterodyne phase measurement technique is used. The sample measured is placed in a muffle furnace with two coaxial holes opened on the opposite furnace walls. The measurement beams hit perpendicularly and coaxially on each surface of the sample. The reference beams hit on the reference mirror and the high-refiectivity mirror, respectively. By the heterodyne configuration and computing, the influences of the vibration, distortion of the sample supporter and the effect of variations in the refractive index are measured and largely minimized. For validation, the TECs of aluminum samples are determined in the temperature range of 29-748K, confirming not only the precision within 5 × 10-7 K-1 and the accuracy within 0.4% from 298K to 448K but also the high sensitivity non-contact measurement of the lower reflectivity surface induced by the sample oxidization from 448 K to 748 K.

In-situ measurement and distribution of flue gas mercury for a utility PC boiler system

The in-situ instrumentation technique for measuring mercury and itsspeciation downstream a utility 100 MW pulverized coal (PC) fired boiler system was developed andconducted by the use of the Ontario hydro method (OHM) consistent with American standard test methodtogether with the semi-continuous emissions monitoring (SCEM) system as well as a mobile laboratoryfor mercury monitoring. The mercury and its speciation concentrations including participate mercuryat three locations of before air preheater, before electrostatic precipitator (ESP) and after ESPwere measured using the OHM and SCEM methods under normal operation conditions of the boiler systemas a result of firing a bituminous coal. The vapor-phase total mercury Hg(VT) concentration declinedwith the decrease of flue gas temperature because of mercury species transformation from oxidizedmercury to particulate mercury as the flue gas moved downstream from the air preheater to the ESPand after the ESP. A good agreement for Hg°, Hg^(2+) and Hg( VT) was obtained between the twomethods in the ash-free area. But in the dense particle-laden flue gas area, there appeared to be abig bias for mercury speciation owing to dust cake formed in the filter of OHM sampling probe. Theparticulateaffinity to the flue gas mercury and the impacts of sampling condition to accuracy ofmeasure were discussed.

Preliminary Results of In-situ Stress Measurements along the Longmenshan Fault Zone after the Wenchuan M_s 8.0 Earthquake

Four months after the Wenchuan Ms 8 earthquake in western Sichuan, China, in situ stress measurements were carried out along the Longmenshan fault zone with the purpose of obtaining stress parameters for earthquake hazard assessment. In-situ stresses were measured in three new boreholes by using overcoring with the piezomagnetic stress gauges for shallow depths and hydraulic fracturing for lower depths. The maximum horizontal stress in shallow depths （-20 m） is about 4.3 MPa, oriented N19°E, in the epicenter area at Yingxiu Town, about 9.7 MPa, oriented N51°W, at Baoxing County in the southwestern Longmenshan range, and about 2.6 MPa, oriented N39°E, near Kangding in the southernmost zone of the Longmenshan range. Hydraulic fracturing at borehole depths from 100 to 400 m shows a tendency towards increasing stress with depth. A comparison with the results measured before the Wenchuan earthquake along the Longmenshan zone and in the Tibetan Plateau demonstrates that the stress level remains relatively high in the southwestern segment of the Longmenshan range, and is still moderate in the epicenter zone. These results provide a key appraisal for future assessment of earthquake hazards of the Longmenshan fault zone and the aftershock occurrences of the Wenchuan earthquake.

A distributed measurement method for in-situ soil moisture content by using carbon-fiber heated cable

Moisture content is a fundamental physical index that quantifies soil property and is closely associatedwith the hydrological, ecological and engineering behaviors of soil. To measure in-situ soil moisturecontents, a distributed measurement system for in-situ soil moisture content （SM-DTS） is introduced.The system is based on carbon-fiber heated cable （CFHC） technology that has been developed to enhancethe measuring accuracy of in-situ soil moisture content. Using CFHC technique, a temperature characteristicvalue （Tt） can be defined from temperatureetime curves. A relationship among Tt, soil thermalimpedance coefficient and soil moisture content is then established in laboratory. The feasibility of theSM-DTS technology to provide distributed measurements of in-situ soil moisture content is verifiedthrough field tests. The research reported herein indicates that the proposed SM-DTS is capable ofmeasuring in-situ soil moisture content over long distances and large areas.

Advance of in-situ stress measurement in China

In-situ stress is an essential parameter for design and construction of most engineering projects that involve excavation in rocks. Progress in in-situ stress measurement from the 1950s in China is briefly introduced. Stress relief by overcoring technique and hydraulic fracturing： technique are the two main techniques for in-situ stress measurement in China at present. To make them suitable for application at great depth and to increase their measuring reliability and accuracy, a series of techniques have been developed. Applications and achievements of in-situ stress measurement in Chinese rock engineering, including mining, geotechnical and hydropower engineering, and earthquake prediction, are introduced. Suggestions for further development of in-situ stress measurement are also proposed.

Development of in-situ Marine Sediment Geo-Acoustic Measurement System with Real-Time and Multi Frequencies (the Second Generation)

Compared with the laboratory acoustic measurement of sediment samples, the in-situ acoustic measurement in marine sediment is considered more accurate and rehable, because it covers all of the surrounding environment factors and avoids the disturbance during the course of sampling and transporting of sediment samples. A new multi-frequency in-situ geoacoustic measurement system （MFIS^AMS） has been developed. The system can provide acoustic vdocity （compressional wave） and attenuation profiles of the uppermost 4 - 8 m sediment in the seafloor. It consists of 8 channels with 12 frequencies （multi-frequencies） and 0.5 - 2 MHz sampling rates. The data collected can be transmiuted in real-time. Associated with inclinometer and altimeter, it can provide the data for depth emendation. Acoustic velocity and attenuation data have been obtained from two in-situ experiments conducted in the Hangzhou Bay.

ONLINE GRINDING WHEEL WEAR COMPENSATION BY IMAGE BASED MEASURING TECHNIQUES

Automatic compensation of grinding wheel wear in dry grinding is accomplished by an image based online measurement method. A kind of PC-based charge-coupled device image recognition system is schemed out, which detects the topography changes of the grinding wheel surface. Profile data, which corresponds to the wear and the topography, is measured by using a digital image processing method. The grinding wheel wear is evalualed by analyzing the position deviation of the grinding wheel edge. The online wear compensation is achieved according to the measure results. The precise detection and automatic compensation system is integrated into an open structure CNC curve grinding machine. A practical application is carried out to fulfil the precision curve grinding. The experimental results confirm the benefits of the proposed techniques, and the online detection accuracy is less than 5 um. The grinding machine provides higher precision according to the in-process grinding wheel error compensation.

New development of hydraulic fracturing technique for in-situ stress measurement at great depth of mines

In-situ stress measurement using the hydraulic fracturing technique was made at Wanfu Coal Mine in Shandong Province, China. To solve problems caused by great measuring depth and extra thick overburden soil layers in the mine, a series of improved techniques were developed for the traditional hydraulic fracturing technique and equipment to increase their pressure-enduring ability and to ensure safe and flexible removal of the sealing packers with other experimental apparatus. Successful in-situ stress measurement at 37 points within 7 boreholes, which were mostly over 1000 m deep, was completed. Through the measurement, detailed information of in-situ stress state has been provided for mining design of the mine. The improved hydraulic fracturing technique and equipment also provide reliable tools for in-situ stress measurement at great depth of other mines.

A low-cost in-situ CO_(2) sensor based on a membrane and NDIR for long-term measurement in seawater

The multi-point simultaneous long-term measurement of CO_(2) concentration in seawater can provide more-valuable data for further understanding of the spatial and temporal distribution of CO_(2).Thus,the requirement for a low-cost sensor with high precision,low power consumption,and a small size is becoming urgent.In this work,an in-situ sensor for CO_(2) detection in seawater,based on a permeable membrane and non-dispersive infrared(NDIR)technology,is developed.The sensor has a small size(Ф66 mm×124 mm),light weight(0.7 kg in air),low power consumption(<0.9 W),low cost(<US$1000),and high-pressure tolerance(<200 m).After laboratory performance tests,the sensor was found to have a measurement range of(0–2000)×10^(-6),and the gas linear correlation R^(2) is 0.99,with a precision of about 0.98%at a sampling rate of 1 s.A comparison measurement was carried out with a commercial sensor in a pool for 7 days,and the results showed a consistent trend.Further,the newly developed sensor was deployed in Qingdao nearshore water for 35 days.The results proved that the sensor could measure the dynamic changes of CO_(2) concentration in seawater continuously,and had the potential to carry out long-term observations on an oceanic platform.It is hoped that the sensor could be applied to field ocean observations in near future.

Analysis on method for effective in-situ stress measurement in hot dry rock reservoir

With the rapid increase of energy demand and the increasingly highlighted environmental problems, clean, safe and widely distributed geothermal resources have become a hot spot for renewable resources development. The state of in-situ stress is a major control parameter for multiple links including well location, fracture inspiration and reservoir assessment, so how to determine the accurate state of in-situ stress in the deep thermal reservoir becomes a core problem drawing widely attention and urgent to be solved. Based on features of hot dry rock reservoir in terms of temperature and pressure and the comparison analysis, this article proposes the method of Anelastic Strain Recovery(ASR) as an effective method for determining the state of in-situ stress in the area with HDR resources distributed and explains the availability of ASR method by application examples.

Techniques for in-situ stress measurement at great depth

Reliable information of in--situ stress state is necessary for the design andconstruction of most important rock projects. As most rock projects are getting deeper and deeper,traditional techniques of in--situ stress measurement are not very suitable. The current techniquesof in--situ stress measurement and their insufficiency for use at great depth are analyzed. Somebasic ideas of the development of new techniques and the improvement of current techniques for useat great depth are provided.

Distribution laws of abutment pressure around fully mechanized top-coal caving face by in-situ measurement

In order to obtain the distribution rules of abutment pressure around the 1151 （3） fully mechanized top-coal caving （FMTC） face of Xieqiao Colliery, the KSE-II-1 type bore-hole stress gauges were installed in the tailentry and headentry to measure the mining-induced stress. The distribution rules of the front and side abutment pressure were demonstrated. The results show that distribution rules of stress are obviously different in the vicinity of the face and entries. The peak value of abutment pressure in the protective coal pillar and face are located commonly in front of the working face along the strike, and they are located at the stress-decreased zone near the face. There is no stress peak value in the lateral coal mass beside the headentry in front of the face on the strike, and the peak value of abutment pressure appears at the rear area of the face. There are stress peak values both in the protective coal pillar and in the lateral coal mass beside the headentry to the dip.

Tests of new in-situ seabed acoustic measurement system in Qingdao

A new in-situ seabed acoustic measurement system is developed for direct in-situ measurement of sediment geoacoustic properties （compressional wave velocity and attenuation）. The new in-situ system consists of two parts： the deck control unit and the underwater measurement unit. The underwater measurement unit emits sonic waves that propagate through the seafloor sediment, receives the returning signals, and transmits them to the deck control unit for waveform display and analysis. The entire operation is controlled and monitored in real time by the deck control unit on the research vessel and can provide recording of full waveforms to determine the sound velocity and attenuation. This paper outlines the design of the system, the measurement process, and demonstrates its application in tests carded out on seabed sediment off the Qingdao coast, China. The test results show that the system performed well and rapidly provided accurate in-situ acoustic velocity and attenuation estimates of the seafloor sediment.

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.

In-situ multi-information measurement system for preparing gallium nitride photocathode

We introduce the first domestic in-situ multi-information measurement system for a gallium nitride （GaN） photo- cathode. This system can successfully fulfill heat cleaning and activation for GaN in an ultrahigh vacuum environment and produce a GaN photocathode with a negative electron affinity （NEA） status. Information including the heat clean- ing temperature, vacuum degree, photocurrent, electric current of cesium source, oxygen source, and the most important information about the spectral response, or equivalently, the quantum efficiency （QE） can be obtained during prepa- ration. The preparation of a GaN photocathode with this system indicates that the optimal heating temperature in a vacuum is about 700 ~C. We also develop a method of quickly evaluating the atomically clean surface with the vacuum degree versus wavelength curve to prevent possible secondary contamination when the atomic level cleaning surface is tested with X-ray photoelectron spectroscopy. The photocurrent shows a quick enhancement when the current ratio between the cesium source and oxygen source is 1.025. The spectral response of the GaN photocathode is flat in a wavelength range from 240 nm to 365 nm, and an abrupt decline is observed at 365 nm, which demonstrates that with the in-si$u multi-information measurement system the NEA GaN photocathode can be successfully prepared.

In-situ 3D contour measurement for laser powder bed fusion based on phase guidance

In-situ layerwise imaging measurement of laser powder bed fusion(LPBF)provides a wealth of forming and defect data which enables monitoring of components quality and powder bed homogeneity.Using high-resolution camera layerwise imaging and image processing algorithms to monitor fusion area and powder bed geometric defects has been studied by many researchers,which successfully monitored the contours of components and evaluated their accuracy.However,research for the methods of in-situ 3D contour measurement or component edge warping identification is rare.In this study,a 3D contour mea-surement method combining gray intensity and phase difference is proposed,and its accuracy is verified by designed experiments.The results show that the high-precision of the 3D contours can be achieved by the constructed energy minimization function.This method can detect the deviations of common ge-ometric features as well as warpage at LPBF component edges,and provides fundamental data for in-situ quality monitoring tools.

DYNAMIC COMPENSATION OF MEASURING SYSTEMS BY SYSTEM IDENTIFICATION APPROACH

A digital filtering method is presented to compensate the dynamic characteristics of measuring systems.The compensation filter has an infinite impulse response property and is designed by system identification approach from the known input output pairs of the measuring system.Applications of this method to eliminating the distortions of measured waveform in transient pulse measurement are investigated.Experimental results show that the measurement errors caused by the sensor are reduced to be very small after the use of the compensation filter.

Reliability analysis of in-situ stress measurement using circumferential velocity anisotropy

In-situ stress measurement for deep reservoir formation is difficult in terms of security, reliability and technique. Acoustic velocity anisotropy test is a basic method for stress measurement of rock cores, which is based on the distribution of acoustic velocity in different directions around rock cores. The heterogeneity of core samples, such as fractures and gravel contained, can also lead to wave velocity anisotropy. Therefore, the corresponding reliability evaluation method is established to exclude some other anisotropy factors caused by non-tectonic stresses. In this paper, the reliability of testing results is evaluated from three aspects, i.e. phase difference, anisotropy index and waveform, to remove the factors caused by non-tectonic stresses.