面形自适应超声在机测厚方法研究

doi:10.3901/JME.2018.18.011

机械工程学报 ›› 2018, Vol. 54 ›› Issue (18): 11-17.doi: 10.3901/JME.2018.18.011

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面形自适应超声在机测厚方法研究

刘海波^1,2, 廉盟¹, 周连杰¹, 应杨威¹, 王永青^1,2

1. 大连理工大学精密与特种加工教育部重点实验室大连 116024;
2. 辽宁重大装备制造协同创新中心大连 116024

收稿日期:2017-09-13 修回日期:2018-04-15 出版日期:2018-09-20 发布日期:2018-09-20
通讯作者: 廉盟(通信作者),女,1989年出生,博士研究生。主要研究方向为在机精密测量。E-mail:corinnalian@mail.dlut.edu.cn
作者简介:刘海波,男,1983年出生,博士,副教授,硕士研究生导师。主要研究方向为测量-加工一体化、在机数字化测量等。E-mail:hbliu@dlut.edu.cn
基金资助:
国家重点基础研究发展计划（973计划，2014CB046604）和国家自然科学基金创新研究群体（51621064）资助项目。

Research on Shape Adaptive Thickness On-machine Measurement Using Ultrasonic

LIU Haibo^1,2, LIAN Meng¹, ZHOU Lianjie¹, YING Yangwei¹, WANG Yongqing^1,2

1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024;
2. Collaborative Innovation Center of Major Machine Manufacturing in Liaoning, Dalian 116024

Received:2017-09-13 Revised:2018-04-15 Online:2018-09-20 Published:2018-09-20

摘要/Abstract

摘要： 针对复杂曲面薄壁零件高效、精密在机测厚难题，提出一种面形自适应的超声在机测厚新方法，创新设计多功能高度集成的超声在机测厚装置，进一步建立超声在机扫描测厚运动控制基本模型。通过基于静力平衡的测量位姿解算和基于首次回波能量衰减的姿态偏角自动辨识，确定出传感器动态调整中的最佳测量姿态。对于具有固定时延的超声回波信号，利用所构造的步长控制函数，设计回波声时变步长自适应计算算法，可有效提高算法收敛速率和减小稳态误差。以弧形和S形薄壁件为典型对象，利用所研发的超声在机测厚系统，开展面形自适应超声在机测厚综合试验研究。试验表明，对在机测量的厚度数据实施姿态偏角误差补偿，其结果与三坐标测量机标定值相比较，测量精度可稳定在0.02 mm以内，满足了复杂薄壁零件在机测厚需求。

关键词: 薄壁件, 超声, 面形自适应, 声时计算, 在机测厚, 姿态偏角

Abstract: Precise and efficient thickness on-machine measurement is a challenging problem for complex thin-walled parts. A shape adaptive thickness on-machine measurement method using ultrasonic is developed. A multi-function integrated ultrasonic thickness on-machine measuring device is innovatively designed, and a basic measurement motion control model is further established. The best measuring posture of ultrasonic sensor in dynamic adjustment can be determined, through the position and pose calculation based on static force equilibrium and the posture angle error automatic identification based on first echo energy attenuation. For echo signals with fixed time delays, a variable step size adaptive algorithm for ultrasonic time of flight(TOF) calculation is designed using a novel step control function, which can improve the convergence rate and reduce the steady-state error effectively. Taking the arc-and S-thin-walled parts as typical objects, the experimental study is conducted using the proposed method. It shows that the ultrasonic thickness on-machine measurement accuracy with posture angle error compensation can be controlled within 0.02 mm by comparing with coordinate measuring machine(CMM) calibration, which could meet the requirements of thickness on-machine measurement of complexed thin-wall parts.

Key words: on-machine thickness measurement, posture angle, shape adaptive, thin-walled part, TOF calculation, ultrasonic

中图分类号:

TH821

刘海波, 廉盟, 周连杰, 应杨威, 王永青. 面形自适应超声在机测厚方法研究[J]. 机械工程学报, 2018, 54(18): 11-17.

LIU Haibo, LIAN Meng, ZHOU Lianjie, YING Yangwei, WANG Yongqing. Research on Shape Adaptive Thickness On-machine Measurement Using Ultrasonic[J]. Journal of Mechanical Engineering, 2018, 54(18): 11-17.

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面形自适应超声在机测厚方法研究

Research on Shape Adaptive Thickness On-machine Measurement Using Ultrasonic

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