CN112344875A - Automatic measurement planning method for turbine blade - Google Patents

Automatic measurement planning method for turbine blade Download PDF

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CN112344875A
CN112344875A CN202011103843.6A CN202011103843A CN112344875A CN 112344875 A CN112344875 A CN 112344875A CN 202011103843 A CN202011103843 A CN 202011103843A CN 112344875 A CN112344875 A CN 112344875A
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奚学程
朱思萌
马洁宇
熊蓉
闫晓燊
张亚欧
赵万生
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    • G—PHYSICS
    • G01—MEASURING; TESTING
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Abstract

The invention relates to a technology in the field of turbine blade profile measurement. The method comprises the steps of firstly, uniformly meshing the curved surface contour of the turbine blade, extracting uniformly distributed point clouds to be measured from a turbine blade design model, and then fitting a local tangent plane to calculate the normal vector of the point to be measured. And then, performing kinematic modeling on the measuring machine tool, and performing kinematic inverse solution by combining the coordinates and normal vectors of the points to be measured to obtain the normal measuring attitude of each point to be measured. And converting the planning problem of the measurement sequence among the points to be measured into an optimization problem, wherein the optimization target is that the movement time of the machine tool is shortest in the measurement process, and the optimization is carried out through an ant colony algorithm. And finally, automatically generating a measuring program according to the normal measuring postures and the measuring sequence of the points to be measured, executing the profile measurement of the turbine blade, and analyzing the measuring result into an actually measured point cloud according to the structure of the machine tool. The invention improves the measurement precision and shortens the measurement time.

Description

Automatic measurement planning method for turbine blade
Technical Field
The invention relates to a technology in the field of turbine blade contour measurement, in particular to a turbine blade measuring method for planning a normal measurement track based on an ant colony algorithm.
Background
The turbine blade is a key part in an aircraft engine, and as the turbine blade is formed by one-time precision casting, a large profile error exists on the outer profile, and in order to test the casting profile precision of the turbine blade and provide a process reference for subsequent processing, the profile of each turbine blade needs to be measured on line. In production practice, the online measurement of the turbine blade has high requirements on measurement accuracy and measurement speed.
The laser displacement sensor is a measuring device commonly used in the field of turbine blade profile measurement due to high measurement precision, measurement speed, stability and flexibility. However, the measurement accuracy of the laser displacement sensor is reduced along with the increase of the included angle between the laser ray and the local normal direction of the turbine blade, and meanwhile, the outer contour of the turbine blade is a complex free-form surface, so that the measurement track planning difficulty is high.
In the prior art, a contour measurement track of a turbine blade is generally planned by adopting a contour method, contour lines are extracted along the contour section of the turbine blade, points to be measured are uniformly distributed on the contour lines, and the measurement is carried out along the normal direction in the contour section. The measurement planning method is simple, but the laser ray is not completely adjusted to be vertical to the local profile of the turbine blade, the distribution of the measurement point cloud on the surface of the turbine blade is not uniform, and the measurement speed is low, so that the method is difficult to be suitable for online measurement of the turbine blade.
Disclosure of Invention
In view of the above-mentioned defects of the prior art, the technical problem to be solved by the present invention is to realize automatic generation of a turbine blade measurement program, improve measurement accuracy, shorten measurement time, and improve measurement efficiency.
In order to achieve the above object, the present invention provides an automatic measurement planning method for turbine blades, which is used for online automatic measurement of turbine blade profiles, and is characterized by comprising the following steps:
step 1, performing two-dimensional grid division on a curved surface outline area of a turbine blade design model, and controlling point cloud density by adjusting the size of grid units;
step 2, extracting unit nodes from the two-dimensional grid to be used as point clouds to be detected;
step 3, solving neighborhood point clouds of each point to be detected;
step 4, fitting a plane to the neighborhood point cloud, and taking the normal direction of the plane as the measurement direction of the current point to be measured;
step 5, combining the structure of the measuring machine to establish a kinematic model of the machine tool;
step 6, aligning the laser ray direction with the measurement direction of the points to be measured, realizing normal measurement, and solving the measurement attitude of each point to be measured;
step 7, calculating a nominal distance matrix according to the unit speeds of different motion axes and the motion distances of all axes between the points to be measured;
step 8, optimizing the measurement time through an optimization algorithm to generate a measurement sequence of the points to be measured;
step 9, combining the measurement attitude and the measurement sequence of the point to be measured, and automatically generating a measurement program;
step 10, executing the measuring program, measuring the profile of the turbine blade, and storing the machine tool attitude and the measuring result during each measurement;
and 11, converting the measurement result into a point cloud on a workpiece coordinate system according to the machine tool kinematic model.
Further, in step 1, the two-dimensional grid is divided into a plurality of grids which are uniformly distributed.
Further, in step 5, the measuring machine is a Z-Y-X-B-C configuration measuring machine.
Further, in step 5, the machine tool kinematic model is established through a momentum theory.
Further, in step 7, before the nominal distance matrix is calculated, the unit speeds of the different motion axes are used to perform normalization processing on the motion distances of the axes between the points to be measured.
Further, in step 8, the optimization algorithm is an ant colony algorithm.
The invention has the beneficial effects that:
the method comprises the steps of firstly, uniformly meshing the curved surface contour of the turbine blade, extracting uniformly distributed point clouds to be measured from a turbine blade design model, and calculating a normal vector of the point to be measured by fitting a local tangent plane. And then, performing kinematic modeling on the measuring machine tool, and performing kinematic inverse solution by combining the coordinates and normal vectors of the points to be measured to obtain the normal measuring attitude of each point to be measured. And converting the planning problem of the measurement sequence among the points to be measured into an optimization problem, wherein the optimization target is that the movement time of the machine tool is shortest in the measurement process, and the optimization is carried out through an ant colony algorithm. And finally, automatically generating a measuring program according to the normal measuring postures and the measuring sequence of the points to be measured, executing the profile measurement of the turbine blade, and analyzing the measuring result into an actually measured point cloud according to the structure of the machine tool.
The invention realizes the automatic generation of the turbine blade measuring program, improves the measuring precision, shortens the measuring time, improves the measuring efficiency and obtains good technical effect.
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
Drawings
FIG. 1 is a flow chart of the turbine blade point to be measured extraction according to a preferred embodiment of the present invention;
FIG. 2 is a schematic view of the point cloud location and normal orientation of the turbine blade under test according to a preferred embodiment of the present invention;
FIG. 3 is a schematic view of a Z-Y-X-B-C configuration measuring machine according to a preferred embodiment of the present invention;
FIG. 4 is a schematic diagram of a normal measurement according to a preferred embodiment of the present invention;
FIG. 5 is a schematic diagram of the measurement trajectory optimization of the preferred embodiment of the present invention;
FIG. 6 is a schematic diagram of a measurement trajectory planning according to a preferred embodiment of the present invention;
FIG. 7 is a schematic view of a turbine blade measured point cloud according to a preferred embodiment of the present invention.
The device comprises a laser displacement sensor 1 and a turbine blade 2.
Detailed Description
The technical contents of the preferred embodiments of the present invention will be more clearly and easily understood by referring to the drawings attached to the specification. The present invention may be embodied in many different forms of embodiments and the scope of the invention is not limited to the embodiments set forth herein.
In the drawings, structurally identical elements are represented by like reference numerals, and structurally or functionally similar elements are represented by like reference numerals throughout the several views. The size and thickness of each component shown in the drawings are arbitrarily illustrated, and the present invention is not limited to the size and thickness of each component. The thickness of the components may be exaggerated where appropriate in the figures to improve clarity.
Firstly, parameters of points to be measured of the turbine blade are extracted.
In order to improve the representativeness of the measurement result, the measurement points should actually fit the workpiece and be distributed on the surface to be measured as uniformly as possible, and the points to be measured are extracted from the design model of the turbine blade 2, and the extraction process is shown in fig. 1. Firstly, uniform two-dimensional mesh division is carried out on a curved surface contour region of a design model of the turbine blade 2, and the top points of each mesh unit are extracted to form a turbine blade 2 curved surface contour feature point cloud. And solving the neighborhood point cloud for each point in the turbine blade 2 curved surface contour feature point cloud. And solving the local normal direction of the current position by fitting the neighborhood tangent plane. The measuring speed of the actually measured point cloud of the curved surface profile of the turbine blade 2 influences the production rhythm of the whole flexible manufacturing unit. In order to shorten the measurement time, the point cloud to be measured is subjected to uniform sparsification, and the point cloud to be measured and the normal direction are obtained as shown in fig. 2.
Then, the normal measurement attitude of each point to be measured is calculated.
Taking a Z-Y-X-B-C configuration measuring machine as an example, a kinematic model is established. As shown in fig. 3, the laser displacement sensor 1 is fixed to the end of the Z-axis actuator, and the workpiece and the jig are fixed to the C-axis stage. According to the machine tool configuration, three coordinate systems are respectively established: machine tool coordinate system OMWorkpiece coordinate system OWMeasuring coordinate system OL. The machine tool coordinate system is fixed relative to the machine tool, the origin point is a BC axis intersection point, and the XYZ coordinate axes of the coordinate system are respectively parallel to the XYZ motion axes of the machine tool. And the measuring coordinate system is fixed on a Z axis, the origin is the tail end of the Z-axis actuator, three coordinate axes of the coordinate system are respectively parallel to XYZ motion axes of the machine tool, and the machine tool coordinate system is coincided with the origin of the measuring coordinate system when the XYZ readings of the machine tool are set to be (0,0, 0). The workpiece coordinate system is fixed on the C axis, the origin point is a BC axis intersection point, and when the BC axis reading of the machine tool is (0,0), the machine tool coordinate system is consistent with the XYZ coordinate axis directions of the workpiece coordinate system.
Setting a point Q in the machine tool space, and the coordinates of the point Q on the machine tool coordinate system, the workpiece coordinate system and the measurement coordinate system are QM、qW、qLThen the transformation relationship between the coordinate systems can be expressed as:
qM＝GML·qL (1)
qM＝GMW·qW (2)
Figure BDA0002726295830000031
wherein G isMLAs a machine tool coordinate system OMAnd a measurement coordinate system OLA transfer matrix of GMWAs a machine tool coordinate system OMAnd the workpiece coordinate system OWA transfer matrix of GWLAs a coordinate system O of the workpieceWAnd a measurement coordinate system OLThe transfer matrix of (2).
The readings of each axis of the machine tool are respectively (theta)x，θy，θz，θb，θc) Then the above-mentioned data is transmittedThe transition matrix is respectively:
Figure BDA0002726295830000041
Figure BDA0002726295830000042
Figure BDA0002726295830000043
due to the fact that the laser displacement sensor 1 has geometric deflection errors, the actual laser ray direction is not parallel to the Z axis. When the laser ray is not perpendicular to the surface to be measured, an object plane inclination angle error is generated, and as the workpiece inclination angle increases, the measurement error also increases. In order to improve the precision of the measured point cloud of the turbine blade 2, it should be ensured that the laser ray is perpendicular to the local surface of the point to be measured of the turbine blade 2 as much as possible. As shown in FIG. 4, the upper side is a schematic view of measurement of the laser displacement sensor 1, and the lower side is a schematic view of a normal direction of a point to be measured of the turbine blade 2. If the measuring range midpoint of the laser displacement sensor 1 is set to be L, the ideal position of the point to be measured on the measuring coordinate system is set to be qL1Is (0,0, -L), and qL2(0,0, -L +1) is the distance q on the laser beamL1A point of unit length. Obtaining a point q to be measured based on a design modelW1The unit vector of the normal direction of the point to be measured is (n)x，ny，nz) Then q isW2＝(x+nx，y+ny，z+nz) Is a distance q in the normal direction of the point to be measuredW1A point of unit length. When the laser displacement sensor 1 measures the point vector
Figure BDA0002726295830000044
Normal vector of point to be measured of turbine blade 2
Figure BDA0002726295830000045
When the measurement machine is coincident, the measurement machine is in an ideal measurement posture. Are respectively substituted into the formula (3) to construct the gateIn the transfer matrix GWLThe system of equations of (1):
Figure BDA0002726295830000046
and solving the matrix equation set (7) to obtain the measurement program under the ideal measurement attitude. Setting machine tool axis reading (theta)x，θy，θz，θb，θc) Then G isWLIs (theta)x，θy，θz，θb，θc) And (3) an expression of the composition.
qW2-qW1＝GWL·(qL2-qL1) (8)
Substituting equation (6) into the equation, the simplification can be:
Figure BDA0002726295830000047
the mechanical structure limits the rotation range of the B shaft to [ -90 DEG, 90 DEG ]]Left and right rotational symmetry without thetab∈[0°，90°]. C-axis rotation unrestricted, do not set thetac∈[0°，360°]. Then theta can be obtainedbAnd thetacIs determined. The formula (6) and thetab、θcSubstituting equation (7-1), we can simply:
Figure BDA0002726295830000051
solving the matrix equation (10) to obtain thetax、θy、θzIs determined. Will (theta)x，θy，θz，θb，θc) And (4) carrying in, automatically generating a measuring program, and realizing the normal measurement of the point to be measured.
Then, the measurement sequence among the points to be measured is planned.
The complete measurement program needs to control the machine tool to make the laser displacement sensor 1 traverse all the points to be measured in a certain sequence along the normal direction. Because the single measurement time is the same, the movement speeds of the machine tool movement axes are the same under the same feed multiplying power, and the movement time of the machine tool between two adjacent measurements is reduced and the measurement speed is increased only by optimizing the measurement sequence of each point to be measured. Therefore, the turbine blade 2 measurement track planning problem can be abstracted to an optimization problem of the shortest measurement time by optimizing the measurement sequence of the points to be measured, and is a traveler problem in a special machine tool motion space.
In the normal measurement program, the machine tool movement distance between two actual points to be measured is analyzed as the independent movement distance of each axis according to the formulas (9) and (10). Let the measurement postures of the two points to be measured respectively be (theta)x1，θy1，θz1，θb1，θc1) And (theta)x2，θy2，θz2，θb2，θc2) And then the motion distance vector of the machine tool between the two points to be measured is as follows:
Figure BDA0002726295830000052
the XYZ axis is a moving axis and has a unit of millimeter, the BC axis is a rotating axis and has a unit of radian, meanwhile, the driving speeds of the axes are different, and the increment of the movement distance cannot strictly represent the movement time of the machine tool between two points to be measured. Unit speed (theta) when each shaft is independently drivenx，θy，θz，θb，θc) Normalizing the motion distance vector of the machine tool to obtain a motion time vector of the machine tool between two points to be measured:
Figure BDA0002726295830000053
between two adjacent measurements, the measurement program controls each axis to move independently, so that the switching of the measurement attitude is realized, and the movement axis which consumes the longest time determines the movement switching time. Therefore, the nominal distance between two points to be measured, i.e. the actual movement time of the machine tool between the two points to be measured, can be defined as:
Figure BDA0002726295830000054
constructing a nominal distance matrix between every two adjacent points to be measured:
Figure BDA0002726295830000055
let the traversal order of n points to be measured be r1，r2，r3，...，rnThe nominal distance of movement between two adjacent measurements is }
Figure BDA0002726295830000056
The total nominal distance of the traversal of the point to be measured is:
Figure BDA0002726295830000057
the total nominal distance in the measurement process is optimized through the ant colony algorithm, the convergence curve is shown in fig. 5, and the obtained measurement track is shown in fig. 6.
And finally, automatically generating a measuring program according to the measuring attitude of each point to be measured and the measuring sequence of all the points to be measured.
Executing a measuring program, recording the measuring result of the laser displacement sensor 1 and the five-axis coordinate corresponding to the measuring attitude during each measurement, wherein each obtained measuring record consists of 6 parameters (theta)x，θy，θz，θb，θcL). Firstly, obtaining the coordinate q of an actual measuring point under a laser coordinate systemL(0,0, -L). Then, a transformation matrix G between the laser coordinate system and the workpiece coordinate system is usedWLAnd carrying out coordinate transformation on the actual measurement point coordinates to obtain the coordinates of the actual measurement point in a workpiece coordinate system:
qW＝GWL·qL(16)
reading all the measurement results in sequence, and changing coordinates to obtain actual measurement point cloud data of the workpiece to be measured in the workpiece coordinate system, wherein the actual measurement point cloud data is shown in fig. 7.

Claims (6)

1. A turbine blade automatic measurement planning method is used for online automatic measurement of a turbine blade profile and is characterized by comprising the following steps:
step 1, performing two-dimensional grid division on a curved surface outline area of a turbine blade design model, and controlling point cloud density by adjusting the size of grid units;
step 2, extracting unit nodes from the two-dimensional grid to be used as point clouds to be detected;
step 3, solving neighborhood point clouds of each point to be detected;
step 4, fitting a plane to the neighborhood point cloud, and taking the normal direction of the plane as the measurement direction of the current point to be measured;
step 5, combining the structure of the measuring machine to establish a kinematic model of the machine tool;
step 6, aligning the laser ray direction with the measurement direction of the points to be measured, realizing normal measurement, and solving the measurement attitude of each point to be measured;
step 7, calculating a nominal distance matrix according to the unit speeds of different motion axes and the motion distances of all axes between the points to be measured;
step 8, optimizing the measurement time through an optimization algorithm to generate a measurement sequence of the points to be measured;
step 9, combining the measurement attitude and the measurement sequence of the point to be measured, and automatically generating a measurement program;
step 10, executing the measuring program, measuring the profile of the turbine blade, and storing the machine tool attitude and the measuring result during each measurement;
and 11, converting the measurement result into a point cloud on a workpiece coordinate system according to the machine tool kinematic model.
2. The method for automatic measurement planning for a turbine blade of claim 1 wherein in step 1, the two-dimensional grid is divided into a uniform distribution.
3. The method for automatic measurement planning of a turbine blade of claim 1 wherein in step 5, the measuring machine is a Z-Y-X-B-C configuration measuring machine.
4. A method for automatic measurement planning of a turbine blade according to claim 1 wherein in step 5 the machine tool kinematics model is established by a vorticity theory.
5. The method for automatically measuring and planning turbine blades according to claim 1, wherein in step 7, before calculating the nominal distance matrix, the unit speeds of the different motion axes are used to normalize the motion distances of the axes between the points to be measured.
6. The method for automatic measurement planning for turbine blades of claim 1 wherein in step 8, said optimization algorithm is an ant colony algorithm.
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