WO2024066181A1 - 一种轴类工件键槽对称度在位非接触检测方法 - Google Patents
一种轴类工件键槽对称度在位非接触检测方法 Download PDFInfo
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- WO2024066181A1 WO2024066181A1 PCT/CN2023/077576 CN2023077576W WO2024066181A1 WO 2024066181 A1 WO2024066181 A1 WO 2024066181A1 CN 2023077576 W CN2023077576 W CN 2023077576W WO 2024066181 A1 WO2024066181 A1 WO 2024066181A1
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- keyway
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/26—Measuring arrangements characterised by the use of optical techniques for measuring angles or tapers; for testing the alignment of axes
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- the invention relates to a detection method for shaft workpieces in the field of machining, and in particular to an in-situ non-contact detection method for the symmetry of a keyway of a shaft workpiece.
- the shaft key is usually made of steel and is placed or installed between the paired shaft and the axial hub of the component to achieve the purpose of transmitting motion and preventing relative sliding; the keyway is a groove on the shaft or hub for receiving the key and firmly locking the component.
- Symmetry error is one of the key factors affecting key transmission performance, so symmetry is an important indicator for evaluating keyway quality. Symmetry error should not be too large. If the error is too large, it will cause uneven force on the transmission mechanism and reduce the centering accuracy. In order to ensure the safety of key transmission of shaft parts, the keyway symmetry must be strictly tested.
- the commonly used keyway symmetry detection method is to place the workpiece on a V-shaped block to simulate the reference axis of the shaft, insert a gauge block into the keyway, simulate the center plane of the keyway to be measured with the gauge block, then align the upper plane of the gauge block to be parallel to the measuring table, measure the distance between the two ends of the gauge block, flip it 180° and measure it again, and enter the measured data into the formula to calculate the symmetry error value.
- Another detection method is to use a three-coordinate measuring machine, but the detection cost is high and the detection time is long.
- the existing tool contact measurement method is easy to scratch the surface of the part, has low measurement accuracy and low degree of automation, and cannot meet the needs of today's high-precision and efficient large-scale production model.
- the purpose of the present invention is to provide an on-site non-contact detection method for the symmetry of keyways of shaft workpieces, which improves the accuracy and degree of automation of keyway detection, realizes on-site non-contact detection of keyway processing, and provides a guarantee for high-precision keyway manufacturing.
- the present invention discloses an in-situ non-contact detection method for the symmetry of a keyway of a shaft workpiece, comprising the following steps:
- Step 1 Establish a detection system, which includes a guide rail located on the upper side of the machine tool, a laser displacement sensor installed on the guide rail and capable of moving laterally along the guide rail, a lateral moving device installed on the guide rail for driving the laser displacement sensor to move, longitudinal moving devices located on both sides of the guide rail for driving the longitudinal movement of the guide rail, and a machine tool for clamping shaft workpieces; wherein the measuring direction of the laser displacement sensor is the vertical direction, first move the laser displacement sensor along the guide rail to the non-keyway section of the shaft workpiece, and use the moving devices at both ends of the guide rail to make the guide rail move horizontally perpendicular to the axis of the workpiece, Compare the measured values during the movement, adjust the laser displacement sensor so that it is located at the maximum measurement value position, that is, on the axis of the shaft workpiece, and then move the laser displacement sensor along the guide rail to the top of the keyway of the shaft workpiece; establish a system calculation coordinate system, with the theoretical intersection of the laser and the axis
- Step 2 Control the machine tool to rotate at a given speed, drive the shaft workpiece to rotate at a constant speed, and the laser displacement sensor obtains the real-time detection data of the shaft workpiece, and converts it to obtain the measurement value y on the Y axis;
- R is the shaft radius
- b is the keyway depth
- ⁇ is the polar angle
- ⁇ is the polar diameter
- the width of the keyway is 2a
- ⁇ 0 is the symmetry error of the keyway that actually exists in the section. If there is no symmetry error, ⁇ 0 is 0;
- the detection trajectory equation obtained by the laser displacement sensor can be regarded as the original curve equation formula (2) of the rotation.
- the positive point that intersects with the Y axis within one rotation, the model expression is
- the two numerical mutation points A and B in the detection trajectory are the left and right edge points of the keyway, and their rotation angles are set to ⁇ 1 and ⁇ 2 respectively, ⁇ 1 ⁇ 2 ; let the rotation angle when the value in the trajectory is the smallest be ⁇ 0 , at which time the bottom of the keyway is just parallel to the X-axis, that is, regardless of the initial position of the axis, rotating it counterclockwise by an angle of ⁇ 0 can achieve a horizontal bottom of the keyway. At this position, the coordinates of the two end points of the keyway can be calculated. At this time, points A and B are distributed on both sides of the y-axis, and the horizontal coordinate calculation formulas are
- x A is the horizontal coordinate of point A
- x B is the horizontal coordinate of point B
- the horizontal coordinate of the keyway center point is calculated from the horizontal coordinates of points A and B.
- the difference between the horizontal coordinate and the ideal coordinate is the symmetry error.
- the calculation formula is:
- ⁇ ′ 1 and ⁇ ′ 2 are the rotation angles when the laser displacement sensor detects the edge vertices of the two key slots. By combining them, the detection curve model after the sensor is offset can be obtained;
- the laser displacement sensor has deviation along the x-axis direction, and its maximum and minimum values change. Assume that the maximum value detected after the deviation is R max . R max will be smaller than the cross-sectional radius R. The rotation angle deviation of points A and B is compensated.
- the compensation formula is:
- rs is the compensation angle
- the compensation angle is used to eliminate the influence of the horizontal offset of the laser displacement sensor.
- the calculation formula of the horizontal coordinates of points A and B is:
- Step 3 Move the laser displacement sensor along the Z-axis on the keyway, repeat the detection several times at different positions, and calculate the symmetry error on n sections.
- ⁇ i is the symmetry error value calculated on the i-th section, and ⁇ is the symmetry error of the shaft keyway.
- step 2 the laser displacement sensor obtains the real-time detection data of the shaft workpiece, and the specific method of converting the data into the measurement value y on the Y axis is:
- the laser displacement sensor detection data is mapped to the O-XYZ coordinate system.
- the laser displacement sensor is located on the axis of the keyway segment.
- the measurement value obtained by the laser displacement sensor when the workpiece rotates one circle is y c
- the maximum value is y cmax
- the minimum value excluding the keyway segment value is y cmin .
- the detection data corresponds to the value on the Y axis as y, then the corresponding relationship is:
- the lateral moving device includes a lateral screw rod arranged parallel to and below the guide rail, and a lateral motor connected to the guide rail for driving the lateral screw rod to rotate.
- the laser displacement sensor is fixed on the ball nut seat of the lateral screw rod.
- the lateral motor drives the lateral screw rod to rotate, thereby driving the laser displacement sensor to move laterally along the guide rail.
- the longitudinal moving device includes two parallel longitudinal screws symmetrically arranged on both sides of the guide rail and a longitudinal motor located at the end of the longitudinal screw and used to drive the longitudinal screw to rotate.
- the two ends of the guide rail are fixed on the ball nut seats of the longitudinal screws on both sides.
- the longitudinal motor synchronously drives the longitudinal screws on both sides to rotate, driving the guide rail to move along the longitudinal screw.
- the machine tool includes a chuck for clamping the shaft workpiece and a center for tightening the shaft workpiece, and the rotation of the chuck is controlled to drive the shaft workpiece to rotate at a uniform speed.
- the present invention adopts a high-precision sensor to detect contour data, and calculates the symmetry error value through the contour trajectory data, thereby avoiding the problem of introducing a measurement reference and easily causing additional errors by using a traditional V-block or measuring block, and taking into account the positioning error of the objectively existing laser displacement sensor and eliminating it in the calculation;
- the present invention can enable a high-precision machining accuracy detection process to be carried out directly on the machining site, and non-contact measurement avoids damage to the machined workpiece and loss of the detection instrument, while avoiding positioning errors caused by multiple clamping;
- the present invention has high reliability, high detection efficiency and short detection time, and can realize in-situ non-contact detection of shaft workpieces of various sizes, and has a high degree of freedom and does not rely on a large number of fixed fixture constraints, and has a wide range of applicability.
- FIG1 is a schematic diagram of a calculation coordinate system of the present invention.
- Fig. 2 is a schematic diagram of the process of the present invention.
- FIG3 is a schematic diagram of the structure of the detection system of the present invention.
- FIG. 4 is a top view of the guide rail of the present invention.
- the present invention provides a non-contact in-situ detection method for the symmetry of a keyway of a shaft workpiece, comprising the following steps:
- Step 1 Establish a detection system, which includes a guide rail located on the upper side of the machine tool, a laser displacement sensor installed on the guide rail and capable of moving laterally along the guide rail, a lateral moving device installed on the guide rail for driving the movement of the laser displacement sensor, a longitudinal moving device located on both sides of the guide rail and used to drive the longitudinal movement of the guide rail, and a machine tool for clamping shaft workpieces; wherein the lateral moving device includes a lateral screw rod arranged in parallel below the guide rail, a lateral motor connected to the guide rail for driving the lateral screw rod to rotate, the laser displacement sensor is fixed on the ball nut seat of the lateral screw rod, and the lateral motor drives the lateral screw rod to rotate, thereby driving the laser displacement sensor to move laterally along the guide rail.
- the lateral moving device includes a lateral screw rod arranged in parallel below the guide rail, a lateral motor connected to the guide rail for driving the lateral screw rod to rotate, the laser displacement sensor is fixed on the ball nut seat of the
- the longitudinal moving device includes two longitudinal screw rods arranged in parallel and symmetrically arranged on both sides of the guide rail, and a longitudinal motor located at the end of the longitudinal screw rod and used to drive the longitudinal screw rod to rotate.
- the two ends of the guide rail are fixed on the ball nut seats of the longitudinal screw rods on both sides.
- the longitudinal motor synchronously drives the longitudinal screw rods on both sides to rotate, driving the guide rail to move along the longitudinal screw rod.
- the machine tool includes a chuck for clamping shaft workpieces and a top for tightening shaft workpieces.
- the measuring direction of the laser displacement sensor is vertical.
- the laser displacement sensor is first moved along the guide rail to the non-keyway section of the shaft workpiece, and the guide rail is moved horizontally perpendicular to the axis of the workpiece through the moving devices at both ends of the guide rail.
- the measured values during the movement are compared, and the laser displacement sensor is adjusted so that it is located at the maximum measurement value position, that is, on the axis of the shaft workpiece.
- the laser displacement sensor is moved along the guide rail to above the keyway of the shaft workpiece; a system calculation coordinate system is established, with the theoretical intersection of the laser and the axis of the shaft workpiece as the origin O, the axis of the shaft workpiece as the Z axis, the vertical upward straight line where the laser is located as the positive direction of the Y axis, the X axis is determined by the right-hand rule, and the detection coordinate system O-XYZ is established.
- the section detected by the laser displacement sensor is the XOY plane;
- Step 2 Control the chuck of the machine tool to rotate at a given speed, drive the shaft workpiece to rotate at a constant speed, and the laser displacement sensor obtains the real-time detection data of the shaft workpiece, and converts it to obtain the measurement value y on the Y axis;
- the laser displacement sensor obtains the real-time detection data of the shaft workpiece, and the specific method of converting the measured value y on the Y axis is as follows:
- the laser displacement sensor detection data is mapped to the O-XYZ coordinate system.
- the laser displacement sensor is located on the axis of the keyway segment.
- the measurement value obtained by the laser displacement sensor when the workpiece rotates one circle is y c
- the maximum value is y cmax
- the minimum value excluding the keyway segment value is y cmin .
- the detection data corresponds to the value on the Y axis as y, then the corresponding relationship is:
- R is the shaft radius
- b is the keyway depth
- ⁇ is the polar angle
- ⁇ is the polar diameter
- the width of the keyway is 2a
- ⁇ 0 is the symmetry error of the keyway that actually exists in the section. If there is no symmetry error, ⁇ 0 is 0;
- the detection trajectory equation obtained by the laser displacement sensor can be regarded as the original curve equation formula (2) of the rotation.
- the positive point that intersects with the Y axis within one rotation, the model expression is
- the two numerical mutation points A and B in the detection trajectory are the left and right edge points of the keyway, and their rotation angles are set to ⁇ 1 and ⁇ 2 respectively, ⁇ 1 ⁇ 2 ; let the rotation angle when the value in the trajectory is the smallest be ⁇ 0 , at which time the bottom of the keyway is just parallel to the X-axis, that is, regardless of the initial position of the axis, rotating it counterclockwise by an angle of ⁇ 0 can achieve a horizontal bottom of the keyway. At this position, the coordinates of the two end points of the keyway can be calculated. At this time, points A and B are distributed on both sides of the y-axis, and the horizontal coordinate calculation formulas are
- x A is the horizontal coordinate of point A
- x B is the horizontal coordinate of point B
- the horizontal coordinate of the keyway center point is calculated from the horizontal coordinates of points A and B.
- the difference between the horizontal coordinate and the ideal coordinate is the degree of symmetry.
- the error is calculated as:
- ⁇ ′ 1 and ⁇ ′ 2 are the rotation angles when the laser displacement sensor detects the edge vertices of the two key slots. By combining them, the detection curve model after the sensor is offset can be obtained;
- the laser displacement sensor has deviation along the x-axis direction, and its maximum and minimum values change. Assume that the maximum value detected after the deviation is R max . R max will be smaller than the cross-sectional radius R. The rotation angle deviation of points A and B is compensated.
- the compensation formula is:
- rs is the compensation angle
- the compensation angle is used to eliminate the influence of the horizontal offset of the laser displacement sensor.
- the calculation formula of the horizontal coordinates of points A and B is:
- Step 3 Move the laser displacement sensor along the Z-axis on the keyway, repeat the detection several times at different positions, and calculate the symmetry error on n sections.
- ⁇ i is the symmetry error value calculated on the i-th section
- ⁇ is the symmetry error of the shaft keyway.
- the detection device laser displacement sensor is selected as a certain LK-H150 type, with an accuracy of 0.25um and a measurable range of 150 ⁇ 40mm.
- the shaft workpiece 1 is fixed by the chuck 3 and the center 4 on the machine tool.
- a detection system needs to be established. It should be noted that the position of the laser displacement sensor 2 should be adjusted so that it is as far as possible above the axis of the shaft workpiece 1 to be measured, and a detection system coordinate system should be established, as shown in Figure 1.
- the core is to represent the cross-sectional contour of the keyway; the chuck 3 is controlled to rotate and then drive the shaft workpiece 1 to rotate at a uniform speed. The rotation speed is an important variable in the calculation.
- the laser displacement sensor 2 continuously collects data from the rotating part, and performs point calculation based on the collected data.
- the symmetry error value of the cross-sectional keyway is obtained by substituting it into the calculation formula; if the symmetry error value of a cross section is known and the overall symmetry error of the keyway is required, the laser displacement sensor 2 is moved along the guide rail 5 to calculate the symmetry error values of the keyways of multiple cross sections, and the maximum value is taken as the overall symmetry error value of the keyway.
- a non-contact and efficient detection method for the symmetry of a keyway of a shaft workpiece comprises the following steps:
- Step 1 Establish a detection system, as shown in Figures 3 and 4, the detection system includes a guide rail 5 located on the upper side of the machine tool, a laser displacement sensor 2 installed on the guide rail and capable of moving laterally along the guide rail, a lateral moving device installed on the guide rail for driving the laser displacement sensor to move, a longitudinal moving device located on both sides of the guide rail and used to drive the guide rail to move longitudinally, and a machine tool for clamping shaft workpieces; wherein the lateral moving device includes a lateral screw rod 7 arranged in parallel below the guide rail, a lateral motor 8 connected to the guide rail for driving the lateral screw rod to rotate, the laser displacement sensor 2 is fixed on the ball nut seat 9 of the lateral screw rod 7, and the lateral motor 8 drives the lateral screw rod 7 to rotate, thereby driving the laser displacement sensor 2 to move laterally along the guide rail 5.
- the lateral moving device includes a lateral screw rod 7 arranged in parallel below the guide rail, a lateral motor 8 connected to the guide rail for driving the lateral
- the longitudinal moving device includes two longitudinal screw rods 6 arranged in parallel and symmetrically arranged on both sides of the guide rail, and a longitudinal motor 10 located at the end of the longitudinal screw rod and used to drive the longitudinal screw rod to rotate, the two ends of the guide rail 5 are fixed on the ball nut seats 11 of the longitudinal screw rods 6 at both ends, and the longitudinal motor 10 synchronously drives the longitudinal screw rods 6 on both sides to rotate, driving the guide rail 5 to move along the longitudinal screw rod 6.
- the shaft workpiece is fixed by the chuck 3 and the center 4 of the machine tool, and the measurement direction of the laser displacement sensor 2 is the vertical direction.
- the laser displacement sensor detection data corresponds to the O-XYZ coordinate system.
- the radius of the keyway segment axis is 20mm, and the laser displacement sensor is located on the axis of the keyway segment.
- the maximum value of the laser displacement sensor measured after the workpiece rotates one circle is 22.474mm, and the minimum value excluding the keyway segment value is 17.522mm.
- the detection data corresponds to the value on the Y axis as y, so the corresponding relationship is:
- Step 2 Control the chuck 3 to rotate at a given speed, driving the workpiece 1 to rotate at a constant speed.
- the laser displacement sensor 2 obtains real-time detection data of the shaft workpiece 1, and the measurement value y on the Y-axis can be obtained after conversion.
- the laser displacement sensor detects the rotation angles ⁇ ′ 1 and ⁇ ′ 2 of the two keyway edge vertices as 0.1450 ⁇ and 0.3380 ⁇ , respectively, and ⁇ ′ 0 is 0.2864 ⁇ .
- the detection curve model after the sensor is offset can be obtained.
- the maximum measurement value is 19.998mm, so the compensation angle is
- the horizontal coordinates of points A and B are -5.9643 and 5.9774 respectively.
- the calculated symmetry error of the detected section is 0.0065 mm.
- Step 3 Move the laser displacement sensor 2 on the keyway along the Z-axis direction, repeat the detection several times at different positions, calculate the symmetry error on n sections, and obtain a detection value of the keyway symmetry error of 0.011, which is close to the actual error.
- the detection accuracy of this experimental equipment is very high.
Abstract
一种轴类工件（1）键槽对称度在位非接触检测方法，包括建立检测系统并建立系统计算坐标系；控制轴类工件（1）转动，激光位移传感器（2）对检测部位进行连续数据采集，对采集的数据进行计算分析，获得检测截面的对称度误差；沿轴线方向移动激光位移传感器（2），计算键槽多个截面的对称度误差值，得到工件键槽的对称度误差。通过实时检测的轴类工件（1）键槽截面的轮廓信息来计算键槽的对称度误差值，避免了传统使用顶针基准或V形块引入基准所带来的系统误差以及补偿的困难，针对客观存在的激光位移传感器（2）的定位误差进行了消除，确保检测结果的准确性。
Description
本发明涉及加工领域中轴类工件的检测方法，尤其涉及一种轴类工件键槽对称度在位非接触检测方法。
键传动是机械传动的重要形式，轴键通常是由钢制成，并且被放置或安装在所配对轴和所述部件的轴向轮毂之间，以达到传递运动、防止相对滑动的目的；键槽是轴上或轮毂上的凹槽，用于接收键并牢固地锁定组件。
对称度误差是键传动性能的关键影响因素之一，因此，对称度是评价键槽质量的重要指标。对称度误差不应较大，如该误差较大，则会引起传动机构受力不均，对中精度降低。为保证轴类零件键传动的安全性，必须要对键槽对称度进行严格的检测。
目前，常用的键槽对称度检测方法主要是将工件置于V形块上，用以模拟轴的基准轴线，在键槽中插入量块，被测键槽的中心平面用量块模拟，然后找正量块的上平面与测量台面平行，分别测量出量块两端距离，翻转180°后再次测量，将测量数据带入公式计算得到对称度误差值。另一种检测方法是采用三坐标测量仪，但检测成本较高，检测时间长。现有量具接触式测量方法易划伤零件表面、测量精度低、自动化程度低的问题，无法适应当今高精高效规模化生产模式的需要。
因此，亟待解决上述问题。
发明内容
发明目的：本发明的目的提供一种轴类工件键槽对称度在位非接触检测方法，提升了键槽检测的精度以及自动化程度，实现了键槽加工的在位非接触检测，为高精度键槽制造提供保障。
本发明公开了一种轴类工件键槽对称度在位非接触检测方法，包括如下步骤：
步骤1：建立检测系统，检测系统包括位于机床上侧的导轨，安装于导轨上并可沿导轨横向移动的激光位移传感器、安装在导轨上用于驱动激光位移传感器移动的横向移动装置，位于导轨两侧且用于带动导轨纵向运动的纵向移动装置以及用于装夹轴类工件的机床；其中激光位移传感器的测量方向为竖直方向，先将激光位移传感器沿导轨移动至轴类工件的非键槽段，通过导轨两端的移动装置使导轨沿垂直于工件轴线水平移动，
比较移动过程中的测量数值，调节使得激光位移传感器位于最大测量值位置，即位于轴类工件轴线上，然后将激光位移传感器沿导轨移动到轴类工件的键槽上方；建立系统计算坐标系，以激光与轴类工件轴线的理论交点为原点O，轴类工件轴线作为Z轴，激光所在直线竖直向上为Y轴正方向，利用右手定则确定X轴，建立检测坐标系O-XYZ，激光位移传感器所检测的截面即为XOY平面；
步骤2：控制机床按给定转速转动，带动轴类工件匀速旋转，激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y；
在截面直角坐标系X-O-Y上，键槽底部水平时键槽横截面轮廓线数学模型可表示为：
式中，R为轴半径，b为键槽深度，θ为极角，ρ为极径，键槽的宽度为2a，δ0为该截面实际存在的键槽的对称度误差，若不存在对称度误差，则δ0为0；
在截面直角坐标系X-O-Y下，轮廓上一点(x0,y0)绕原点逆时针旋转角度α后的坐标为(x,y)，其转换公式为
激光位移传感器获得检测轨迹方程可视为旋转的原曲线方程公式(2)旋转一周内与Y轴相交的正值点，模型表达式为
检测轨迹中存在的两个数值突变点A、B即为键槽左、右边缘点，其旋转角度分别设为α1和α2，α1＜α2；设轨迹中数值最小时的旋转角度为α0，该时刻键槽底部刚好与X轴平行，即无论轴的初始位置，将其逆时针旋转α0角，则可以实现键槽底部水平，在此位置可计算键槽两端点坐标，此时A、B点分布在y轴两侧，横坐标计算公式分别为
xA为A点的横坐标，xB为B点横坐标；
由A、B点的横坐标，计算出键槽中心点的横坐标，其与理想坐标的差值为对称度误差，计算公式为：
激光位移传感器安装时存在沿X方向的定位误差，当激光位移传感器在x方向偏移距离l时，在截面直角坐标系X-O-Y中，检测直线变为x＝l；键槽段轨迹由检测光线检测到A、B点时的旋转角度所决定；根据空间几何理论，非键槽段的轨迹未发生变化，将公式(4)中的检测直线由x＝0变为x＝l，即可得到A、B点的旋转角度，此时一个周期内的轨迹方程可表示为
α′1、α′2分别是激光位移传感器检测到两键槽边缘顶点时的旋转角度，通过联立可得到传感器存在偏移后的检测曲线模型；
取y值为R-b时且在最低点时刻之后的点为水平时刻点，该旋转角度即为α′0；
激光位移传感器沿x轴方向存在偏差，其测量最大值、最小值都发生变化，设偏移后检测到的数值最大值为Rmax，Rmax将小于截面半径R，对A、B点旋转角度偏移进行补偿，补偿公式为
rs为补偿角度；
利用补偿角消除激光位移传感器水平方向偏移带来的影响，A、B点的横坐标计算公式为
将xA、xB带入公式(6)中即可得到该截面消除传感器偏移误差后的对称度误差计
算值；
步骤3：将激光位移传感器沿Z轴方向在键槽上移动，在不同位置重复数次检测，计算n个截面上的对称度误差，其最大值为键槽的对称度误差，表达式为
δ＝max(δi)，i＝1,2,…n (10)
δ＝max(δi)，i＝1,2,…n (10)
δi为第i个截面上计算的对称度误差值，δ为轴键槽的对称度误差。
其中步骤2中激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y的具体方法为：
将激光位移传感器检测数据在O-XYZ坐标系上对应，激光位移传感器位于键槽段轴线上，设工件旋转一周激光位移传感器得到的测量值为yc，最大值为ycmax，除键槽段数值外的最小值为ycmin，检测数据对应Y轴上的数值为y，则对应关系为
优选的，横向移动装置包括位于导轨下方平行设置的横向丝杆、与导轨相连用于驱动横向丝杆转动的横向电机，激光位移传感器固定在横向丝杆的滚珠螺母座上，横向电机驱动横向丝杆转动，从而带动激光位移传感器沿导轨横向移动。
进一步，纵向移动装置包括对称设置在导轨两侧的两根平行设置的纵向丝杆以及位于纵向丝杆端部且用于驱动纵向丝杆转动的纵向电机，导轨的两端固定在两侧的纵向丝杆的滚珠螺母座上，纵向电机同步驱动两侧纵向丝杆转动，带动导轨沿纵向丝杆移动。
再者，机床包括用于装夹轴类工件的卡盘以及用于顶紧轴类工件的顶尖，控制卡盘转动进而带动轴类工件匀速旋转。
有益效果：与现有技术相比，本发明具有以下显著优点：
首先本发明采用高精度传感器进行轮廓数据检测，通过轮廓轨迹数据计算出对称度误差值，避免了传统V形块或测量块引入测量基准、容易造成附加误差的问题，同时考虑到客观存在的激光位移传感器的定位误差，并在计算中进行了消除；本发明可使高精度的加工精度检测过程直接在加工现场上进行，非接触测量避免了对加工工件的损伤和检测仪器的损耗，同时避免多次装夹所带来的定位误差；相比于其他检测方法，本发明可靠性高、检测效率高且时间短，可实现对各种尺寸轴类工件的在位非接触检测，且自由度高不依赖大量的固定夹具约束，并具有广泛的适用性。
图1为本发明的计算坐标系示意图；
图2为本发明的流程示意图；
图3为本发明中检测系统的结构示意图；
图4为本发明中导轨的俯视图。
下面结合附图对本发明的技术方案作进一步说明。
如图2所示，本发明一种轴类工件键槽对称度在位非接触检测方法，包括如下步骤：
步骤1：建立检测系统，检测系统包括位于机床上侧的导轨，安装于导轨上并可沿导轨横向移动的激光位移传感器、安装在导轨上用于驱动激光位移传感器移动的横向移动装置，位于导轨两侧且用于带动导轨纵向运动的纵向移动装置以及用于装夹轴类工件的机床；其中横向移动装置包括位于导轨下方平行设置的横向丝杆、与导轨相连用于驱动横向丝杆转动的横向电机，激光位移传感器固定在横向丝杆的滚珠螺母座上，横向电机驱动横向丝杆转动，从而带动激光位移传感器沿导轨横向移动。纵向移动装置包括对称设置在导轨两侧的两根平行设置的纵向丝杆以及位于纵向丝杆端部且用于驱动纵向丝杆转动的纵向电机，导轨的两端固定在两侧的纵向丝杆的滚珠螺母座上，纵向电机同步驱动两侧纵向丝杆转动，带动导轨沿纵向丝杆移动。机床包括用于装夹轴类工件的卡盘以及用于顶紧轴类工件的顶尖，激光位移传感器的测量方向为竖直方向，先将激光位移传感器沿导轨移动至轴类工件的非键槽段，通过导轨两端的移动装置使导轨沿垂直于工件轴线水平移动，比较移动过程中的测量数值，调节使得激光位移传感器位于最大测量值位置，即位于轴类工件轴线上，然后将激光位移传感器沿导轨移动到轴类工件的键槽上方；建立系统计算坐标系，以激光与轴类工件轴线的理论交点为原点O，轴类工件轴线作为Z轴，激光所在直线竖直向上为Y轴正方向，利用右手定则确定X轴，建立检测坐标系O-XYZ，激光位移传感器所检测的截面即为XOY平面；
步骤2：控制机床的卡盘按给定转速转动，带动轴类工件匀速旋转，激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y；
其中激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y的具体方法为：
将激光位移传感器检测数据在O-XYZ坐标系上对应，激光位移传感器位于键槽段轴线上，设工件旋转一周激光位移传感器得到的测量值为yc，最大值为ycmax，除键槽段数值外的最小值为ycmin，检测数据对应Y轴上的数值为y，则对应关系为
在截面直角坐标系X-O-Y上，键槽底部水平时键槽横截面轮廓线数学模型可表示为：
式中，R为轴半径，b为键槽深度，θ为极角，ρ为极径，键槽的宽度为2a，δ0为该截面实际存在的键槽的对称度误差，若不存在对称度误差，则δ0为0；
在截面直角坐标系X-O-Y下，轮廓上一点(x0,y0)绕原点逆时针旋转角度α后的坐标为(x,y)，其转换公式为
激光位移传感器获得检测轨迹方程可视为旋转的原曲线方程公式(2)旋转一周内与Y轴相交的正值点，模型表达式为
检测轨迹中存在的两个数值突变点A、B即为键槽左、右边缘点，其旋转角度分别设为α1和α2，α1＜α2；设轨迹中数值最小时的旋转角度为α0，该时刻键槽底部刚好与X轴平行，即无论轴的初始位置，将其逆时针旋转α0角，则可以实现键槽底部水平，在此位置可计算键槽两端点坐标，此时A、B点分布在y轴两侧，横坐标计算公式分别为
xA为A点的横坐标，xB为B点横坐标；
由A、B点的横坐标，计算出键槽中心点的横坐标，其与理想坐标的差值为对称度
误差，计算公式为：
激光位移传感器安装时存在沿X方向的定位误差，当激光位移传感器在x方向偏移距离l时，在截面直角坐标系X-O-Y中，检测直线变为x＝l；键槽段轨迹由检测光线检测到A、B点时的旋转角度所决定；根据空间几何理论，非键槽段的轨迹未发生变化，将公式(4)中的检测直线由x＝0变为x＝l，即可得到A、B点的旋转角度，此时一个周期内的轨迹方程可表示为
α′1、α′2分别是激光位移传感器检测到两键槽边缘顶点时的旋转角度，通过联立可得到传感器存在偏移后的检测曲线模型；
取y值为R-b时且在最低点时刻之后的点为水平时刻点，该旋转角度即为α′0；
激光位移传感器沿x轴方向存在偏差，其测量最大值、最小值都发生变化，设偏移后检测到的数值最大值为Rmax，Rmax将小于截面半径R，对A、B点旋转角度偏移进行补偿，补偿公式为
rs为补偿角度；
利用补偿角消除激光位移传感器水平方向偏移带来的影响，A、B点的横坐标计算公式为
将xA、xB带入公式(6)中即可得到该截面消除传感器偏移误差后的对称度误差计算值；
步骤3：将激光位移传感器沿Z轴方向在键槽上移动，在不同位置重复数次检测，计算n个截面上的对称度误差，其最大值为键槽的对称度误差，表达式为
δ＝max(δi)，i＝1,2,…n (10)
δi为第i个截面上计算的对称度误差值，δ为轴键槽的对称度误差。
δ＝max(δi)，i＝1,2,…n (10)
δi为第i个截面上计算的对称度误差值，δ为轴键槽的对称度误差。
实施例1
以某柴油机厂所生产的轴件为例，其键槽段的直径为40mm，槽宽为12mm，键槽对称度公差为0.015mm，实际为0.010mm。于是根据检测凸轮轴大小，检测装置激光位移传感器选取某LK-H150型，精度0.25um，可测量范围150±40mm。
轴类工件1由机床上的卡盘3和顶尖4固定，首先需要建立检测系统，要注意的是调节激光位移传感器2的位置使其尽可能位于待测轴类工件1轴线上方，并建立检测系统坐标系，如图1所示，核心是为对键槽截面轮廓进行表示；控制卡盘3转动进而带动轴类工件1匀速旋转，旋转速度是计算的重要变量，激光位移传感器2对旋转部位进行连续数据采集，根据采集的数据进行取点计算，带入计算公式得到截面键槽的对称度误差值；已知得到一个截面的对称度误差值，要求键槽整体的对称度误差，则沿导轨5移动激光位移传感器2，计算多个截面的键槽对称度误差值，取其最大值作为整体的键槽对称度误差值。
如图1和图2所示，本发明的一种轴类工件键槽对称度在位非接触高效检测方法，包括如下步骤：
步骤1：建立检测系统，如图3和图4所示，检测系统包括位于机床上侧的导轨5，安装于导轨上并可沿导轨横向移动的激光位移传感器2、安装在导轨上用于驱动激光位移传感器移动的横向移动装置，位于导轨两侧且用于带动导轨纵向运动的纵向移动装置以及用于装夹轴类工件的机床；其中横向移动装置包括位于导轨下方平行设置的横向丝杆7、与导轨相连用于驱动横向丝杆转动的横向电机8，激光位移传感器2固定在横向丝杆7的滚珠螺母座9上，横向电机8驱动横向丝杆7转动，从而带动激光位移传感器2沿导轨5横向移动。纵向移动装置包括对称设置在导轨两侧的两根平行设置的纵向丝杆6以及位于纵向丝杆端部且用于驱动纵向丝杆转动的纵向电机10，导轨5的两端固定在两端的纵向丝杆6的滚珠螺母座11上，纵向电机10同步驱动两侧纵向丝杆6转动，带动导轨5沿纵向丝杆6移动。
轴类工件由机床的卡盘3及顶尖4固定，激光位移传感器2的测量方向为竖直方向。先将激光位移传感器2沿导轨5移动至非键槽段，通过导轨5两端的纵向移动装置使导轨沿垂直于工件1轴线水平移动，比较移动过程中的测量数值，调节使得激光位移传感器2位于最大测量值位置，即位于工件轴线上，然后将激光位移传感器2沿导轨5移动
到键槽上方。建立系统计算坐标系，以激光与工件轴线的理论交点为原点O，工件轴线作为Z轴，激光所在直线竖直向上为Y轴正方向，利用右手定则确定X轴，建立检测坐标系O-XYZ，激光位移传感器所检测的截面即为XOY平面。
将激光位移传感器检测数据在O-XYZ坐标系上对应。键槽段轴半径为20mm，激光位移传感器位于键槽段轴线上，工件旋转一周激光位移传感器得到的测量最大值为22.474mm，除键槽段数值外的最小值为17.522mm，检测数据对应Y轴上的数值为y，则对应关系为
步骤2：控制卡盘3按给定转速转动，带动工件1匀速旋转，激光位移传感器2获取轴类工件1的实时检测数据，经转换可得到Y轴上的测量数值y。
根据检测结果，激光位移传感器检测到两键槽边缘顶点时的旋转角度α′1、α′2分别是0.1450π、0.3380π，α′0为0.2864π，则
通过联立可得到传感器存在偏移后的检测曲线模型。
考虑到实际存在的激光位移传感器定位误差，测量最大值为19.998mm，则补偿角为
A、B点的横坐标分别为-5.9643、5.9774，计算得到该检测截面的对称度误差为0.0065mm。
步骤3：将激光位移传感器2沿Z轴方向在键槽上移动，在不同位置重复数次检测，计算n个截面上的对称度误差，得到键槽对称度误差的检测值为0.011，与实际误差较为接近，本实验设备检测精度很高。
表1 轴不同截面的检测数据
Claims (5)
- 一种轴类工件键槽对称度在位非接触检测方法，其特征在于，包括如下步骤：步骤1：建立检测系统，检测系统包括位于机床上侧的导轨，安装于导轨上并可沿导轨横向移动的激光位移传感器、安装在导轨上用于驱动激光位移传感器移动的横向移动装置，位于导轨两侧且用于带动导轨纵向运动的纵向移动装置以及用于装夹轴类工件的机床；其中激光位移传感器的测量方向为竖直方向，先将激光位移传感器沿导轨移动至轴类工件的非键槽段，通过导轨两端的移动装置使导轨沿垂直于工件轴线水平移动，比较移动过程中的测量数值，调节使得激光位移传感器位于最大测量值位置，即位于轴类工件轴线上，然后将激光位移传感器沿导轨移动到轴类工件的键槽上方；建立系统计算坐标系，以激光与轴类工件轴线的理论交点为原点O，轴类工件轴线作为Z轴，激光所在直线竖直向上为Y轴正方向，利用右手定则确定X轴，建立检测坐标系O-XYZ，激光位移传感器所检测的截面即为XOY平面；步骤2：控制机床按给定转速转动，带动轴类工件匀速旋转，激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y；在截面直角坐标系X-O-Y上，键槽底部水平时键槽横截面轮廓线数学模型可表示为：
式中，R为轴半径，b为键槽深度，θ为极角，ρ为极径，键槽的宽度为2a，δ0为该截面实际存在的键槽的对称度误差，若不存在对称度误差，则δ0为0；在截面直角坐标系X-O-Y下，轮廓上一点(x0,y0)绕原点逆时针旋转角度α后的坐标为(x,y)，其转换公式为
激光位移传感器获得检测轨迹方程可视为旋转的原曲线方程公式(2)旋转一周内与Y轴相交的正值点，模型表达式为
检测轨迹中存在的两个数值突变点A、B即为键槽左、右边缘点，其旋转角度分别设为α1和α2，α1＜α2；设轨迹中数值最小时的旋转角度为α0，该时刻键槽底部刚好与X轴平行，即无论轴的初始位置，将其逆时针旋转α0角，则可以实现键槽底部水平，在此位置可计算键槽两端点坐标，此时A、B点分布在y轴两侧，横坐标计算公式分别为
xA为A点的横坐标，xB为B点横坐标；由A、B点的横坐标，计算出键槽中心点的横坐标，其与理想坐标的差值为对称度误差，计算公式为：
激光位移传感器安装时存在沿X方向的定位误差，当激光位移传感器在x方向偏移距离l时，在截面直角坐标系X-O-Y中，检测直线变为x＝l；键槽段轨迹由检测光线检测到A、B点时的旋转角度所决定；根据空间几何理论，非键槽段的轨迹未发生变化，将公式(4)中的检测直线由x＝0变为x＝l，即可得到A、B点的旋转角度，此时一个周期内的轨迹方程可表示为
α′1、α′2分别是激光位移传感器检测到两键槽边缘顶点时的旋转角度，通过联立可得到传感器存在偏移后的检测曲线模型；取y值为R-b时且在最低点时刻之后的点为水平时刻点，该旋转角度即为α′0；激光位移传感器沿x轴方向存在偏差，其测量最大值、最小值都发生变化，设偏移后检测到的数值最大值为Rmax，Rmax将小于截面半径R，对A、B点旋转角度偏移进行补偿，补偿公式为
rs为补偿角度；利用补偿角消除激光位移传感器水平方向偏移带来的影响，A、B点的横坐标计算 公式为
将xA、xB带入公式(6)中即可得到该截面消除传感器偏移误差后的对称度误差计算值；步骤3：将激光位移传感器沿Z轴方向在键槽上移动，在不同位置重复数次检测，计算n个截面上的对称度误差，其最大值为键槽的对称度误差，表达式为
δ＝max(δi)，i＝1,2,…n (10)δi为第i个截面上计算的对称度误差值，δ为轴键槽的对称度误差。 - 根据权利要求1所述的一种轴类工件键槽对称度在位非接触检测方法，其特征在于，所述步骤2中激光位移传感器获取轴类工件的实时检测数据，转换得到Y轴上的测量数值y的具体方法为：将激光位移传感器检测数据在O-XYZ坐标系上对应，激光位移传感器位于键槽段轴线上，设工件旋转一周激光位移传感器得到的测量值为yc，最大值为ycmax，除键槽段数值外的最小值为ycmin，检测数据对应Y轴上的数值为y，则对应关系为
- 根据权利要求1所述的一种轴类工件键槽对称度在位非接触检测方法，其特征在于：所述横向移动装置包括位于导轨下方平行设置的横向丝杆、与导轨相连用于驱动横向丝杆转动的横向电机，激光位移传感器固定在横向丝杆的滚珠螺母座上，横向电机驱动横向丝杆转动，从而带动激光位移传感器沿导轨横向移动。
- 根据权利要求1所述的一种轴类工件键槽对称度在位非接触检测方法，其特征在于：所述纵向移动装置包括对称设置在导轨两侧的两根平行设置的纵向丝杆以及位于纵向丝杆端部且用于驱动纵向丝杆转动的纵向电机，导轨的两端固定在两侧的纵向丝杆的滚珠螺母座上，纵向电机同步驱动两侧纵向丝杆转动，带动导轨沿纵向丝杆移动。
- 根据权利要求1所述的一种轴类工件键槽对称度在位非接触检测方法，其特征在于：所述机床包括用于装夹轴类工件的卡盘以及用于顶紧轴类工件的顶尖，控制卡盘转动进而带动轴类工件匀速旋转。
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