CN108073131B - Mirror milling skin appearance error real-time non-contact measurement and compensation device and skin thickness accurate control method - Google Patents

Mirror milling skin appearance error real-time non-contact measurement and compensation device and skin thickness accurate control method Download PDF

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CN108073131B
CN108073131B CN201711307629.0A CN201711307629A CN108073131B CN 108073131 B CN108073131 B CN 108073131B CN 201711307629 A CN201711307629 A CN 201711307629A CN 108073131 B CN108073131 B CN 108073131B
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skin
displacement sensor
laser displacement
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data
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CN108073131A (en
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董志刚
康仁科
鲍岩
王昌瑞
朱祥龙
付海洋
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Dalian University of Technology
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/18Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/401Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/37Measurements
    • G05B2219/37398Thickness

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  • Manufacturing & Machinery (AREA)
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  • Length Measuring Devices By Optical Means (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention discloses a mirror milling skin appearance error real-time non-contact measurement and compensation device and a skin thickness accurate control method, wherein the device comprises a non-contact measurement module and a data processing compensation module; the non-contact type measuring module comprises two laser displacement sensor heads and a laser displacement sensor controller for acquiring the measuring data of the two laser displacement sensor heads; the data processing compensation module comprises a machine tool numerical control system built-in coordinate offset module and a data analysis module which processes the measured data and calls the machine tool numerical control system built-in coordinate offset module according to the processing result to realize the automatic compensation of the skin deformation in the processing. The invention only needs to store the dynamic measurement data between the measurement point and the processing point at a certain moment, reads one data to generate a compensation value, then processes and releases the storage of the data, the amount of the stored data is small, the processing and fitting of the whole skin point cloud data are avoided, and the time of data processing and feedback control is greatly reduced.

Description

Mirror milling skin appearance error real-time non-contact measurement and compensation device and skin thickness accurate control method
Technical Field
The invention relates to a device and a method for accurately controlling machining thickness, in particular to a device and a method for accurately controlling the thickness in mirror milling, and specifically relates to a device for measuring and compensating appearance errors of a skin in mirror milling in a real-time non-contact manner and an accurate control method for the thickness of the skin.
Background
The mirror milling technology is a new technology for numerical control milling of aircraft skin, and a mirror milling system consists of two five-coordinate horizontal machine tools which move synchronously. The spindle of one horizontal machine tool is a processing head, a milling cutter is mounted for processing a skin, the spindle of the other five-axis machine tool is a supporting head, a supporting column is mounted for supporting the skin, and the milling cutter and the supporting column synchronously move on the same normal. In the machining process, the milling cutter and the support column are always opposite to two ends of the skin workpiece, the distance between the milling cutter and the support column is a fixed value, and the fixed value is the machining thickness of the skin. The method always supports the skin processed area, ensures that the skin processed area has enough rigidity, and can realize accurate control of the residual thickness of the skin after processing.
The prior process flow of mirror milling is as follows: the method comprises the steps of firstly horizontally placing the skin, clamping the periphery of the skin in a clamping frame through laser positioning, then automatically turning the flexible clamping frame horizontally-vertically through a rotary table, and entering a processing room. The processing chamber consists of a laser scanning system and a mirror image milling processing system, wherein the laser scanning system is used for scanning the actual appearance of the part, the actual scanning data is compared with the theoretical data of the part after scanning, and a processing program is generated and executed to complete mirror image milling and drilling processing. The processed skin is automatically conveyed back and disassembled by the clamping frame.
In the processing chamber, due to the influence of roll bending or stretch forming errors of skin materials, clamping deformation and the like, deviation is generated between an actual profile and a theoretical profile of the skin, and if a theoretical profile processing program is adopted for processing, larger wall thickness deviation is generated, so that processed parts are unqualified. Therefore, on-machine detection and reverse forming technologies are needed to be adopted to obtain the actual processing shape of the skin, and secondary correction is carried out on the original processing program, so that the problem of wall thickness deviation generated by non-processing deformation such as raw material forming shape error and dead weight is finally solved, and the processing quality is improved.
The prior art has the following defects: because the skin overall dimension is big, and the data bulk of measurement is big, consequently when laser scanning, only measure limited point, obtain skin actual profile point cloud data, handle and the fitting to data, form actual profile, the precision is low. In addition, the existing process flow has no actually measured thickness information before the milling processing of the skin, and although the mirror milling can ensure the equal thickness processing, the supporting surface is often greatly different from a theoretical digital model. When ultrasonic thickness measurement is carried out on line, the support column can be separated from the workpiece, so that thickness data are lost, and online compensation cannot be carried out.
Disclosure of Invention
According to the technical problems, the device for measuring and compensating the shape error of the skin machined by mirror milling in a real-time non-contact mode and the method for accurately controlling the thickness of the skin are provided. The technical means adopted by the invention are as follows:
a mirror milling skin appearance error real-time non-contact measurement and compensation device comprises a non-contact measurement module and a data processing and compensation module;
the non-contact type measuring module comprises two laser displacement sensor heads and a laser displacement sensor controller for collecting the measuring data of the two laser displacement sensor heads;
the two laser displacement sensor heads are respectively fixed on a milling cutter connecting disc with a milling cutter and a support column connecting disc with a support column, the milling cutter connecting disc and the support column connecting disc are respectively connected with a mirror milling machine tool machining head and a mirror milling machine tool support head, the axis of the milling cutter on the milling cutter connecting disc is superposed with the axis of the support column on the support column connecting disc, the two laser displacement sensor heads are oppositely arranged, emitted laser beams are positioned on the same straight line, the straight line is parallel to the axis of the milling cutter, and the distance between the two laser displacement sensor heads is unchanged;
the data processing and compensating module comprises a built-in coordinate offset module of the machine tool numerical control system and a data analysis module which processes the measured data of the two laser displacement sensor heads imported from the laser displacement sensor controller and calls the built-in coordinate offset module of the machine tool numerical control system according to the processing result to realize the automatic compensation of the deformation of the skin in the processing.
The data analysis module is a PC terminal.
The invention also discloses a method for accurately controlling the thickness of the skin according to the mirror milling skin shape error real-time non-contact measurement and compensation device, which comprises the following steps:
s1, generating a processing track program according to the processing requirement;
s2, setting the initial cutting depth of the milling cutter, and starting a machining track program;
s3, initializing the distance between the measuring points of the two laser displacement sensor heads;
s4, setting a plane which passes through a supporting point between the supporting column and the skin and is perpendicular to the axis of the milling cutter as a supporting surface, enabling the straight line and the axis of the milling cutter to synchronously move along a processing track relative to the skin, enabling the two laser displacement sensor heads to measure the skin from the initial positions of the processing track, enabling the laser displacement sensor controller to collect the measurement data of the two laser displacement sensor heads, guiding the measurement data into the data analysis module, and enabling the data analysis module to process the measurement data to obtain a processing result of the thickness of the skin and store the processing result;
and taking the supporting surface as a reference, starting when the milling cutter reaches the initial position of the processing track, calling a coordinate offset module built in a machine tool numerical control system by the data analysis module to realize automatic compensation of skin deformation in processing according to the obtained skin thickness of the corresponding position, carrying out program correction on the cutting depth of the milling cutter to enable the residual skin thickness to reach the requirement, and then releasing the storage of the skin thickness of the position.
The method comprises the steps of firstly measuring along a processing track, then processing, and synchronously moving two laser displacement sensor heads, the milling cutter and the supporting column relative to the skin, so that only dynamic measurement data (skin thickness) between a measuring point and a processing point at a certain moment is required to be stored, one data is read to generate a compensation value, then processing is carried out, the storage of the data is released, the amount of stored data is small, the processing and fitting of the whole skin point cloud data are avoided, and the time for data processing and feedback control is greatly reduced.
In step S3, initializing a distance between the measurement points of the two laser displacement sensor heads includes the steps of: and a measuring block which is vertical to the straight line and has a known thickness is arranged between the two laser displacement sensor heads, measuring points of the two laser displacement sensor heads are respectively positioned on the upper surface and the lower surface of the measuring block, the upper surface is used as an upper measuring reference surface, the lower surface is used as a lower measuring reference surface, the two laser displacement sensor heads are reset, and the distance between the measuring points of the two laser displacement sensor heads is initialized.
In step S4, the measurement data of the two laser displacement sensor heads are: for the position to be processed on the processing track measured by the laser displacement sensor head corresponding to the upper measuring reference surface, if the measuring point is above the upper measuring reference surface, the reading is positive and the reading is recorded, and if the measuring point is below the upper measuring reference surface, the reading is negative and the reading is recorded;
and for the position to be processed on the processing track measured by the laser displacement sensor head corresponding to the lower measuring reference surface, if the measuring point is above the lower measuring reference surface, the reading is negative and the reading is recorded, and if the measuring point is below the lower measuring reference surface, the reading is positive and the reading is recorded.
In step S4, the skin thickness at a location is equal to the sum of the readings of the two laser displacement sensor heads at the location plus the gauge block thickness.
Compared with the prior art, the invention has the following beneficial effects:
1. according to the invention, the thickness of the skin in the processing area is directly measured, the positions of the milling cutter and the support column are adjusted in real time through feedback control, the residual thickness of the processed skin is accurately controlled, and the processing precision is improved.
2. The invention only needs to store dynamic measurement data (skin thickness) between a measurement point and a processing point at a certain moment, reads one data to generate a compensation value, then processes and releases the storage of the data, the amount of stored data is small, the processing and fitting of the whole skin point cloud data are avoided, and the time of data processing and feedback control is greatly reduced.
3. The two laser displacement sensor heads are respectively fixed on a milling cutter connecting disc with a milling cutter and a supporting column connecting disc with a supporting column, an additional control system is not needed, and the control difficulty is low.
4. And the program correction and adjustment are carried out on the cutting depth of the milling cutter in real time according to the skin, so that the cutting parameters can be optimized to the greatest extent, and the processing efficiency is improved.
5. When the shape precision of the skin blank is high, the step of skin surface laser scanning in a processing chamber can be omitted, the processing is directly carried out, and the process flow is simplified.
Based on the reason, the method can be widely popularized in the fields of skin mirror milling and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic structural diagram of a device for real-time non-contact measurement and compensation of skin topography errors by mirror milling in an embodiment of the present invention.
Fig. 2 is a schematic diagram of initialization and measurement of two laser displacement sensor heads in an embodiment of the present invention.
FIG. 3 is a schematic view of the actual locations of the upper and lower surfaces of the treated skin and the thickness of the skin in accordance with an embodiment of the present invention.
Fig. 4 is a schematic diagram of a processing trajectory in an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
As shown in fig. 1, a mirror milling skin appearance error real-time non-contact measurement and compensation device comprises a non-contact measurement module 1 and a data processing and compensation module 2;
the non-contact type measuring module 1 comprises two laser displacement sensor heads 3 and a laser displacement sensor controller 4 for acquiring the measuring data of the two laser displacement sensor heads 3;
the two laser displacement sensor heads 3 are respectively fixed on a milling cutter connecting disc 6 (which is a c shaft of a mirror image milling machine) with a milling cutter 5 and a supporting column connecting disc 8 (which is a c' shaft of the mirror image milling machine) with a supporting column 7, the milling cutter connecting disc 6 and the supporting column connecting disc 8 are respectively connected with a mirror image milling machine processing head 9 and a mirror image milling machine supporting head 10, the axis of the milling cutter 5 on the milling cutter connecting disc 6 is superposed with the axis of the supporting column 7 on the supporting column connecting disc 8, the two laser displacement sensor heads 3 are oppositely arranged, emitted laser beams are positioned on the same straight line, and the straight line is parallel to the axis of the milling cutter 5;
the data processing and compensating module 2 comprises a coordinate offset module 11 arranged in the machine tool numerical control system and a data analysis module 13 which processes the measured data of the two laser displacement sensor heads 3 imported from the laser displacement sensor controller 4 and calls the coordinate offset module 11 arranged in the machine tool numerical control system according to the processing result to realize the automatic compensation of the deformation of the skin 12 in the processing.
The data analysis module 13 is a PC terminal.
Example 2
As shown in fig. 1 to 4, a method for performing skin thickness precise control by using a mirror-image milling skin topography error real-time non-contact measurement and compensation device according to embodiment 1 includes the following steps:
s1, generating a processing track program according to the processing requirement;
s2, setting the initial cutting depth of the milling cutter 5, and starting a machining track program;
s3, initializing the distance between the measuring points of the two laser displacement sensor heads 3;
s4, setting a plane which passes through a supporting point between the supporting column 7 and the skin 12 and is perpendicular to the axis of the milling cutter 5 as a supporting surface, enabling the straight line and the axis of the milling cutter 5 to synchronously move along a processing track relative to the skin 12, enabling the two laser displacement sensor heads 3 to measure the skin 12 from the initial positions of the processing track, enabling the laser displacement sensor controller 4 to collect the measurement data of the two laser displacement sensor heads 3 and guide the measurement data into the data analysis module 13, and enabling the data analysis module 13 to process the measurement data to obtain a processing result of the thickness of the skin 12 and store the processing result;
and taking the supporting surface as a reference, starting when the milling cutter 5 reaches the initial position of the processing track, calling the built-in coordinate offset module 11 of the machine tool numerical control system by the data analysis module 13 to realize automatic compensation of deformation of the skin 12 in the processing according to the obtained thickness of the skin 12 at the corresponding position, carrying out program correction on the cutting depth of the milling cutter 5 to enable the residual thickness of the skin 5 to meet the requirement, and then releasing the storage of the thickness of the skin 12 at the position.
In step S3, initializing the distance between the measurement points of the two laser displacement sensor heads 3 includes the steps of: a gauge block 14 which is perpendicular to the straight line and has a known thickness is arranged between the two laser displacement sensor heads 3, the measuring points of the two laser displacement sensor heads 3 are respectively positioned on the upper surface and the lower surface of the gauge block 14, the upper surface is used as a measuring upper reference surface 15, the lower surface is used as a measuring lower reference surface 16, the two laser displacement sensor heads 3 are cleared, and the distance between the measuring points of the two laser displacement sensor heads 3 is initialized.
In step S4, the measurement data of the two laser displacement sensor heads 3 are: for the position to be processed on the processing track measured by the laser displacement sensor head 3 corresponding to the upper measuring reference surface 15, if the measuring point is above the upper measuring reference surface 15, the reading is positive and the reading is recorded, and if the measuring point is below the upper measuring reference surface 15, the reading is negative and the reading is recorded;
for the position to be processed on the processing trajectory measured by the laser displacement sensor head 3 corresponding to the lower measurement reference surface 16, if the measurement point is above the lower measurement reference surface 16, the index is negative and the index is recorded, and if the measurement point is below the lower measurement reference surface 16, the index is positive and the index is recorded.
In step S4, the thickness L of the skin 12 at a position is equal to the sum (L1+ L2) of the readings of the two laser displacement sensor heads 3 at the position plus the thickness L0 of the gauge block 14.
When the workpiece is machined to the inflection point C, the milling cutter connecting disc 6 and the supporting column connecting disc 8 synchronously rotate at the moment, and the fact that the two laser displacement sensor heads 3 always measure the actual thickness of a small fixed position in front of a machining track is guaranteed.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims (3)

1. A method for accurately controlling the thickness of a skin by a mirror milling skin appearance error real-time non-contact measurement and compensation device,
the mirror milling skin appearance error real-time non-contact measurement and compensation device comprises a non-contact measurement module and a data processing compensation module;
the non-contact type measuring module comprises two laser displacement sensor heads and a laser displacement sensor controller for collecting the measuring data of the two laser displacement sensor heads;
the control method comprises the following steps:
s1, generating a processing track program according to the processing requirement;
s2, setting the cutting depth of the initial milling cutter, and starting a machining track program;
s3, initializing the distance between the measuring points of the two laser displacement sensor heads;
the control method is characterized in that the two laser displacement sensor heads are respectively fixed on a milling cutter connecting disc with a milling cutter and a supporting column connecting disc with a supporting column, and the control method further comprises the following steps:
the milling cutter connecting disc and the support column connecting disc are respectively connected with a mirror milling machine machining head and a mirror milling machine support head, the axis of a milling cutter on the milling cutter connecting disc is superposed with the axis of a support column on the support column connecting disc, the two laser displacement sensor heads are oppositely arranged, emitted laser beams are positioned on the same straight line, and the straight line is parallel to the axis of the milling cutter;
the data processing and compensating module comprises a built-in coordinate offset module of the machine tool numerical control system and a data analysis module which processes the measured data of the two laser displacement sensor heads imported from the laser displacement sensor controller and calls the built-in coordinate offset module of the machine tool numerical control system according to the processing result to realize the automatic compensation of the deformation of the skin in the processing;
s4, setting a plane which passes through a supporting point between the supporting column and the skin and is perpendicular to the axis of the milling cutter as a supporting surface, enabling the straight line and the axis of the milling cutter to synchronously move along a processing track relative to the skin, enabling the two laser displacement sensor heads to measure the skin from the initial positions of the processing track, enabling the laser displacement sensor controller to collect the measurement data of the two laser displacement sensor heads, guiding the measurement data into the data analysis module, and enabling the data analysis module to process the measurement data to obtain a processing result of the thickness of the skin and store the processing result;
taking the supporting surface as a reference, starting when the milling cutter reaches the initial position of a processing track, calling a coordinate offset module built in a machine tool numerical control system by the data analysis module to realize automatic compensation of skin deformation in processing according to the obtained skin thickness of the corresponding position, carrying out program correction on the cutting depth of the milling cutter to enable the residual skin thickness to reach the requirement, and then releasing the storage of the skin thickness of the position;
in step S3, initializing a distance between the measurement points of the two laser displacement sensor heads includes the steps of: and a measuring block which is vertical to the straight line and has a known thickness is arranged between the two laser displacement sensor heads, measuring points of the two laser displacement sensor heads are respectively positioned on the upper surface and the lower surface of the measuring block, the upper surface is used as an upper measuring reference surface, the lower surface is used as a lower measuring reference surface, the two laser displacement sensor heads are reset, and the distance between the measuring points of the two laser displacement sensor heads is initialized.
2. The method for accurately controlling the thickness of the skin by the mirror milling skin shape error real-time non-contact measurement and compensation device according to claim 1, wherein the method comprises the following steps: in step S4, the measurement data of the two laser displacement sensor heads are: for the position to be processed on the processing track measured by the laser displacement sensor head corresponding to the upper measuring reference surface, if the measuring point is above the upper measuring reference surface, the reading is positive and the reading is recorded, and if the measuring point is below the upper measuring reference surface, the reading is negative and the reading is recorded;
and for the position to be processed on the processing track measured by the laser displacement sensor head corresponding to the lower measuring reference surface, if the measuring point is above the lower measuring reference surface, the reading is negative and the reading is recorded, and if the measuring point is below the lower measuring reference surface, the reading is positive and the reading is recorded.
3. The method for accurately controlling the thickness of the skin by the mirror milling skin shape error real-time non-contact measurement and compensation device according to claim 2, characterized in that: in step S4, the skin thickness at a location is equal to the sum of the readings of the two laser displacement sensor heads at the location plus the gauge block thickness.
CN201711307629.0A 2017-12-11 2017-12-11 Mirror milling skin appearance error real-time non-contact measurement and compensation device and skin thickness accurate control method Active CN108073131B (en)

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CN112146582A (en) * 2019-06-29 2020-12-29 上海飞机制造有限公司 Thickness measuring method, device, equipment and storage medium
CN114700813B (en) * 2022-03-14 2024-04-12 金洲精工科技(昆山)有限公司 Method for quickly positioning circumferential direction of tool nose of cylindrical end mill

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