基于双圆光栅的轴系误差测量原理及在齿轮测量中的应用

The automobile gear enterprises urgently need the "high efficiency, high precision, full information" fast inspection technology for the large number of gears, but the gear measuring center and the double-flank rolling tester cannot simultaneously meet the needs. The gear integrated error measuring technology, which is originated in China, has the advantages of high efficiency and full information. So it is the most suitable for the field fast inspection of the automobile gears. However, the accuracy of gear integrated error measuring instrument is not good enough. Essentially, the measurement procedure of gear integrated error consists of only two rotational motions of the worm spindle and the gear spindle. The non-repetitive six-freedom space motion error is the main source of the measuring error of gear integrated error instrument. How to eliminate the adverse effects of spindle error is a key problem that has not been resolved for a long time in the field of gear integrated error measurement..This project puts forward a new on-machine measuring principle of the six-freedom spindle error based on two circular gratings. By addressing the two key scientific issues of measuring the space motion error of spindle by tangential distance sensors and compensating the non-repetitive spindle error of gear integrated error instrument, an on-machine measuring system of spindle dynamic error is established. The system has the advantages of simple structure, high reliability and easy implementation in instruments. Then, the accuracy of the gear integrated error measuring instrument can be substantially improved under the condition of not improving the precision of spindles. Therefore, this project can provide an ideal online fast inspection technology for automobile gear industry, and promote the quality improvement of automobile gear products in our country.

汽车齿轮企业急需面向大批量齿轮的“高效率、高精度、全信息”的快速检测技术，齿轮测量中心和双啮测量仪器都不能同时满足以上需求。由我国首创的齿轮整体误差测量技术具有效率高、信息全的优势，最适合于汽车齿轮现场快速测量，但其测量精度有待提高。齿轮整体误差测量本质上只需要蜗杆主轴和齿轮主轴这两个旋转运动，轴系的非重复性六自由度空间运动误差是主要的测量误差来源。如何消除轴系误差的不利影响是齿轮整体误差测量领域长期未能解决的关键难题。.本课题提出全新的基于双圆光栅的轴系六自由度误差在机测量原理，通过解决基于切向位移传感器的轴系空间运动误差测量和齿轮整体误差量仪非重复性轴系误差补偿这两项关键科学问题，可构建结构简单、可靠性高、易于产品化的轴系动态误差在机测量系统，可实现在不提高轴系精度的条件下大幅提高齿轮整体误差量仪的测量精度，从而为汽车齿轮行业提供理想的在线快速检测技术，推动我国汽车齿轮产品的质量提升。

现有测量技术难以满足对大批量生产齿轮的快速、高精度全检需求。由我国首创的齿轮整体误差测量技术具有效率高、信息全的优势，适用于大批量齿轮现场快速测量，但如何消除其轴系误差的不利影响是长期未能解决的关键难题。本项目主要研究基于双圆光栅的轴系六自由度误差测量原理、面向大批量齿轮的高效率、高精度、全信息检测方法及其应用。提出了基于双圆光栅的轴系六自由度误差测量方法，具有结构简单、成本低、可靠性高、环境适应性强的特点，通过试验验证了可行性和有效性，可实现轴系动态误差的实时测量，有助于提高精密量仪的测量精度。研究了读数头相对于圆光栅发生微量位置移动时的读数变化规律，所建立的数学模型和所发现的数值规律为光栅生产中信号质量调整和使用中的运动部件位置误差修正提供了理论基础。提出了一种新的圆光栅读数头安装误差补偿方法，可使用非精确对径安装的双读数头对圆光栅的偏心误差进行修正，减少了读数头安装误差对测量结果的不利影响，提高了仪器设备在结构设计时的自由度。研究了宏微结合的高精度角度定位转台关键技术，开发了低成本、高角度定位精度的试验转台，补偿后转台的角度定位精度可达到±1”。研制了基于FPGA和ARM芯片的双圆光栅多读数头信号高速同步采集系统样机，可同时接收8路50MHz的光栅脉冲计数信号，同步性能指标在100ns以内。提出了基于双圆光栅的大型零件内孔圆度在位测量装置及仪器安装误差的参数辨识方法，可解决在检测内孔圆度时由于仪器本身的轴系误差和安装误差导致的低精度、低效率的问题。提出了基于双圆光栅的轴承内圈径向跳动测量装置及测量方法，可得到更加接近真实值的轴承内圈径向跳动值。提出了基于双圆光栅的齿轮整体误差测量装置，可以提高齿轮整体误差测量仪器的测量精度。提出了基于影像法的齿轮整体误差测量新方法，开发了新型齿轮整体误差测量仪器，为小模数齿轮行业提供了高效率、全信息、高精度的齿轮在线快速测量技术，已实现技术成果转化及应用。