Key Engineering Materials Vols. 381-382

Abstract: A non-contact on-machine measurement system has been developed since various precise machines are getting lighter and smaller; therefore, processing with nano-precision is demanded recently. This system makes possible to measure with high precision without any damages and it is unnecessary for workpieces to attach or detach from a machine tool. Moreover, this system achieves on-machine form error compensation with high precision. On the other hand, the details of the system performances are still unknown. This study focuses on evaluating the performances by the comparison of the results that measured by this system and an existing measurement instrument under various conditions. As a result, this system shows an equivalent capability of measurement with high precision as the existing measurement instrument.

Abstract: In order to improve the measurement precision, an improved MAP algorithm is proposed to increase the edge aiming precision in this paper. The algorithm breaks the limitation of degenerated model, takes two actual factors into account, one is the distortion caused by motion, which solved by Huber-Markov random filed in the improved MAP algorithm, and the other is curvature of field, which solved by Delaunay triangle method. The algorithm can restore the high-frequency information of image, keep the edge character of image, and increase the aiming precision of the edge during the measurement. The experiments show that the uncertainty of location for the image captured in the measurement can be improved three folds, and the repeatability uncertain is less then 0.8µm when the diameter of φ0.2mm hole is measured using the proposed MAP algorithm and length-measuring interferometer together.

Abstract: In this study, a novel control law including a fine-tuned PID component to yield basic dynamic performance, and a component derived from the Sliding Mode Observer (SMO) to estimate and then compensate for modeling uncertainties and disturbances, has been introduced to planar actuator of an ultra-precision positioning stage. Experimental results are presented to verify the effectiveness of suggested dynamic compensation strategy and tracking performance of the non-contact planar actuator.

Abstract: This paper proposes a methodology for improving the machining accuracy based on auto tool setting & work-piece measuring on the machine using laser tool setting system & inspection probe. In this study, laser tool setting systems were analyzed as considering principles, convenience and efficiency and auto tool setting method and operating macro software were developed. As compared with conventional manual tool setting and touch-type auto tool setting, the importance of automatic non-contact tool setting using laser tool setter has been discussed. Also correct tool-setting methods in accordance with different tool shapes and sizes were defined and pocket features were machined by each of setting tools and measured by the inspection probe system to verify machining accuracy. Lastly we tried to demonstrate the superiority of laser tool setting systems by analyzing the cutting results when the CNC machining center was fitted with laser tool setting system.

Abstract: So-called PV value can reflect the synthetic using performance of sliding bearings and the limit pressure of the lubricant. The newly developed multifunctional tester was introduced in this paper for investigating the PV limit values of bearings, in which the speed spectrum and load spectrum were first timely introduced to simulate the bearings' actual working conditions. In this test-bed, four samples, i.e., four friction couples can be dynamically and synchronously tested and measured. The developed measurement and control software based on object –oriented language has the functions of data collecting, processing, alarming and controlling etc. In the system, several measures have been taken to resist electromagnetism disturbances in both hardware and software parts. The disturbance signals have been effectively screened and restrained, so as to the stability and precision of the tested data have been greatly improved.

Abstract: An optical imaging based fully automatic stereo vision system for aircraft assembly online measurement is presented and analyzed. In this system, the relative position of the two cameras can easily calibrated by imaging an optical reference bar in different locations and orientations throughout the measurement space according to epipolar constraint and the certified distance of the features on the reference bar. For measurement, the system takes infrared LEDs which attached at measured object as imaging targets, and makes use of the measurement results of these feature points space coordinates to calculate the related positions of the assembly aircraft parts. Furthermore, using automatic infrared LED light intensity and CCD cameras exposure time improve the calibration and measurement accuracy. The effectiveness of the proposed system has been test by experiments.

Abstract: Based on an optical structured light method an opto-electronic system for automatic noncontact distant measurements of wear and defects detection for a contact wire electro-supply network is presented. The created industrial system prototype measures the main technological wire parameters, first of all, the remaining height with RMS error down to 0,15 mm and the wire cross-section area with RMS error of 1,5 mm2. Measurement results are sufficient for confident decision about the replacement of worn-out contact wires of electro-supply network. This method is also fit for automatic wire wear measurement and defects detection for trams, trolleybuses and other electro-supply vehicles.

Abstract: The focus of this paper will be on comparison at the measurement of container lids between Advanced TOpometric Optical Sensor - ATOS III SO (GOM mbH) and traditional coordinate measuring machine CMM for the measurement of surfaces - Form Talysurf Series 2 (Taylor Hobson Ltd). In the paper, two kinds of measuring methods (noncontact method at ATOS and contact method at CMM Form Talysurf) and techniques will be made for comparison: digitizing measuring system based on the triangulation principle and traditional measuring systems based on the collecting of points from an object by touching it.

Abstract: Surface structure is a suitability state that must be pursued closely workpiece components which work under severe conditions. It is a fact that high-precision forming component’s surface roughness affects the product’s nature that is being formed. In this scientific perspective, measurement and evaluation of the surface roughness and surface texture diversities during manufacturing and the effects of these diversities on material performance and product suitability has a significant importance. The first objective of the present project is to define surface modification treatments and the surface characteristics which will improve the performance of forming dies particularly for the glass industry. In this experimental work the results of the highprecision measurements on the mould surfaces discussed in detail and the surface characteristics of DIN 1.2080 steel and the surface boronized one of the same material are compared and the effects of surface roughness and surface texture are investigated in a wide perspective.

Abstract: Nowadays more and more scientific papers deal with drilling. The drilling process has been used for more than 5000 years and the development of conventional drills is more than 200 years old. In recent years there have been limited changes to the drill design but considerable improvements have been made in the selection of drill materials, drill coatings, flute design and cutting fluid guiding methods. The paper briefly describes the development of surface characterisation including its current 3D capability. It shows how selected parameters can assist with drill process analysis and how this can be supported through the introduction of the planned new ISO International Standard for 3D Surface characterisation. The paper is supported by a sample drilling test to demonstrate the power of the proposed analysis.