整体结构件光学测量工艺理论数值分析方法研究

The integrated structure part is a new structural component of the modern high-end equipment and plays an important role in improving its performance. However, it’s very difficult to measure the integrated structure part because of its complicated shape. Advancements in CCD sensor technology and projection systems have lead its way to higher precision vision systems and 3D scanners. Optical measurement technique is the most popular to meet the testing requirements of its high efficiency, high precision. The objective of the project is to develop a 3D mesh-based numerical analysis system to reveal mechanism of optical measurement technical theory, to solve key scientific problem of the quality analysis about integrated structure part. 3D scanners only collect information about surfaces that are not obscured. 3D scanners collect distance information about the surface within its field of view. For most situations, a single scan will not produce a complete model of the subject. Multiple scans from many different directions are usually required to obtain information about all the sides of the subject. The methods about measurement path planning, measuring interferometer are proposed based on the three-dimensional mesh technology. The optical measurement technology knowledge base is constructed based on the detection method of detection feature by means of optical measuring experiment. The assessment methods to perform deviation analysis of characteristic parameter are proposed based on optical measurement data, to build a quality analysis theoretical system for integrated structure part. The research results of the project will promote the scientific of optical measurement process design for integrated structure part, to promote the application of optical measurement techniques in the high-end equipment manufacturing, to improve the efficiency and quality of the manufacture of complex products.

整体结构件在提高产品性能方面具有优异的性能，正成为现代高端装备的最主要零件结构形成之一。由于整体结构件的空间复杂性给其检测技术带来了巨大挑战，光学测量技术是满足其高效、高精密检测要求的前沿技术。本项目将基于离散网格技术对整体结构件的光学测量工艺理论展开研究，揭示整体结构件的光学测量工艺形成机理，解决整体结构件质量分析中的关键科学问题。提出基于离散网格技术的光学测量路径规划、测量干涉等问题的计算方法，构建出工艺理论的数值分析模型；通过光学测量物理实验手段获取整体结构件不同检测特征的检测方法，构建出整体结构件的光学测量工艺知识库；提出针对光学测量数据不完整情况下的整体结构件特征参数评估方法，构建出整体结构件的质量分析理论体系。项目的研究成果必将促进整体结构件的光学测量工艺设计问题实现科学化，同时也会促进光学测量技术在高端装备制造中的推广应用，提高复杂产品的制造效率和质量。

在工业生产中，由于设计和测试的需要，各种复杂形状的表面轮廓及尺寸常常被要求测试，从而来判断产品是否合格并加以改进。随着飞机减重、高可靠性、高经济性需求的快速提升，整体结构件用量不断增加。基于整体结构件在提高产品性能方面具有优异的性能，它正成为现代高端装备的最主要零件结构形式之一。整体叶盘作为航空发动机的核心部件，是典型的整体结构件，由于整体叶盘的空间复杂性给其检测技术带来了巨大挑战，光学测量技术是满足其高效、高精密检测要求的前沿技术。本项目通过分析整体叶盘的光学测量问题来研究整体结构件光学测量工艺理论数值分析方法，项目基于离散网格技术对整体叶盘的光学测量工艺展开研究，提出光学测量干涉、路径规划等问题的计算方法，通过光学测量物理实验手段获取整体叶盘检测方法。针对视频测量中不同时刻标志点的对应问题，提出了一种基于轨迹预测的目标跟踪方法。项目还开发了一种基于线激光传感器的四轴测量系统。项目研究成果将促进整体结构件的光学测量工艺设计问题实现科学化，同时也会促进光学测量技术在高端装备制造中的推广应用，提高复杂产品的制造效率和质量，项目成果在汽车等领域也具有广泛的应用前景。