大型圆柱廓形在线高精度测量技术——并行误差分离技术

The problem of the on-line measurement the cylindricity of the high-precision large roller has still not been solved.The parallel error separation techniques (PEST) are proposed here. The facts have been widely known that the spindle error motion presents the periodicity and each harmonic component of the spindle error motion is interrelated. Based on the facts above and making use of parallel processing and the information fusion technology, PEST separates the relative changes of the spindle error motion on the adjacent sections. By accumulating these relative changes and after removing out the error motion of the guide rail, the so-called class-geometric centers are achieved. Linking each class-geometric center into a reference line which usually is not a straight line, the cylindrical shape can be reconstructed. And than the shape parameters, i.e. roundness, circular run-out, taper, cylindricity, straightness and generatrix straightness，of the high-precision large roller（Φ1m×8m）can be measured with the micron accuracy in each meter. The PEST is not directly extract the eccentricity between the rotational center and the geometric center on the measured section round, but rather originally separate the relative differences of the spindle error motion on adjacent sections. The cylindrical shape according with the definition of the cylindricity is reconstruction based on a reference line which links the class-geometric centers on each round. So the PEST is an innovative method not only for on-line precise measurement cylindricity of large roller with high-precision, but also for precise measurement the spindle error motion. Research on the PEST will enrich the existing error separation techniques, and the achievements coming from the PEST are bound to promote the progress of the large-scale equipment manufacturing of our country.

高精度大型轴辊的圆柱廓形在线测量问题至今没有解决。并行误差分离技术基于轴系误差运动规律的周期性和各阶谐波分量的相关性，将并列误差分离与信息融合技术相结合，分离被测轴相邻两个测量截面轴系误差运动一阶谐波分量的相对变化，通过叠加各个测量截面一阶谐波的相对变化、分离并剔除导轨运动误差后，获得各截面类几何中心，以此连线重构大型圆柱廓形，实现高精度大型（Φ0.5~1m×5~8m）轴辊圆柱廓形参数如圆度、锥度、圆柱度和母线直线度测量精度达到每米微米量级。该技术回避了直接萃取测量截面圆度几何中心与回转运动中心偏心的问题，转而分离剔除相临的两个截面圆度测量时的轴系误差运动的相对变化，实现符合圆柱廓形定义的以各截面类几何中心的连线作为基准轴线的圆柱廓形重构。该技术是解决高精度大型轴辊廓形精密在线测量问题的创新方法，也是轴系回转误差运动的高精度测量方法，丰富了误差分离技术，成果将促进国家高端装备制造精度的提升。

1..首先对相关的基础理论开展了研究，包括轴系回转误差运动规律、三点圆度误差分离方法、传感器观测模型等，明确了精确萃取测量截面“类几何中心”矢量是圆柱廓形高精度在线测量重构的关键问题。.2..提出三种并行误差分离方法，基于特别的传感器布局分别建立了萃取“类几何中心”矢量的误差分离数学模型，理论上实现了的全谐波误差分离，精确测定了“空间弯曲中线”，实现了符合ISO定义的圆柱廓形的测量重构。方法解决了精密工程中精确测定被测圆柱中线这一难点问题，实现了圆柱形状精密测试技术理论上的突破。.3..研发完成了卧式实验验证系统。对同一被测圆柱重复测定的中线以及母线廓形有很好的一致性；互比发现两种并行误差分离方法测定的被测圆柱空间弯曲中线廓形有较好的一致性，实验证明了并行误差分离技术在中线测量、圆柱廓形重构上是正确的。.4..提出了两种基于蒙特卡洛方法的圆柱度误差包容评定算法，获得了包容圆柱度误差非线性评定模型的全局最优解，并能够有效面对退化情况。算法解决了圆柱度包容评定非线性极差极小、极大极小和极小极大问题的解算难题，为形状误差高精度包容评定提供了一条有价值的技术路径。.5..基于并行误差分离技术对同一被测圆柱重复测量重构，实现了包容圆柱度误差评定精度±1.0~1.5(μm)/30(μm)；获得的外接和内切约束点位置有较好的一致性并与被测圆柱实际廓形相契合，实验评定证明了并行误差分离技术以及基于蒙特卡洛方法的圆柱度包容评定算法是正确可靠的。.研究解决了两个核心问题：圆柱廓形在线测量重构和圆柱度误差包容评定，在不确定导轨和轴系运动精度的测量环境下实现了高精度的圆柱廓形在线测量重构，进而实现包容圆柱度高精度包容评定。并行误差分离技术将误差分离理论从二维拓展到三维，丰富了形状误差在线测量理论，为大型轴辊廓形在线精密测量提供了有价值方法，成果对提升国家装备制造业科技水平具有重要科学意义和应用价值。