摘要
针对火车轮三维几何参数在线测量中存在的传感器标定流程复杂、工件放置偏心误差等问题,提出了一种基于多个线激光传感器的高精度测量系统及误差修正方法。通过构建多层坐标动态变换模型,实现了不受放置偏心约束下传感器数据到车轮三维几何信息的精准映射;结合分步标定策略,利用立方体、圆柱体及异形回转体标定块,依次标定传感器安装姿态参数与位置参数,并通过位姿微调机构实现多传感器共面校准,解决大型扫描设备装配误差导致的共面难题;针对车轮放置偏心问题,提出基于极坐标动态修正的偏心误差补偿方法,通过实时计算工件轴心偏移量,追踪工件轴心轨迹,显著降低了径向尺寸测量误差,克服了传统机械定心在特殊工况下的局限性。实验结果表明,系统测量绝对误差<±0.069 mm,重复性标准差<0.049 mm,径向尺寸误差修正后波动范围缩减至0.170 mm以内,满足工业级精密测量要求。实际工程应用中,系统对915KKD型车轮的复杂几何特征测量结果与激光跟踪仪基准值的最大相对误差<0.135%,验证了其可靠性与工程适用性。该系统不仅适用于火车车轮的测量,还可推广至其他回转体等工件的三维精密测量场景,为多个线激光传感器旋转扫描测量系统提供了一种通用的标定与误差修正方法。
To address the issues of complex sensor calibration procedures and workpiece eccentricity errors in the online 3D geometric parameter measurement of train wheels,a high-precision measurement system based on multiple line laser sensors and an error correction method are proposed.A multi-layer dynamic coordinate transformation model is constructed to achieve precise mapping from sensor data to the wheel′s 3D geometric information,independent of placement eccentricity constraints.Combining a step-by-step calibration strategy,cube,cylinder,and profiled rotary calibration blocks are used to sequentially calibrate sensor installation pose parameters and position parameters.A pose fine-tuning mechanism enables coplanar calibration of multiple sensors,solving the coplanarity challenge caused by assembly errors in large scanning equipment.For wheel placement eccentricity,an eccentricity error compensation method based on dynamic polar coordinate correction is proposed.By calculating the axis offset in real-time and tracking the workpiece axis trajectory,radial dimension measurement errors are significantly reduced,overcoming the limitations of traditional mechanical centering under special working conditions.Experimental results show that the system′s absolute measurement error is less than±0.069 mm,the repeatability standard deviation is below 0.049 mm,and the fluctuation range of radial dimension errors after correction is reduced to within 0.170 mm,meeting industrial-grade precision measurement requirements.In practical engineering applications,the maximum relative error between the system′s measurement results for complex geometric features of a 915KKD-type wheel and the laser tracker reference values is<0.135%,verifying its reliability and engineering applicability.This system is not only suitable for train wheel measurement but can also be extended to other 3D precision measurement scenarios for rotary workpieces,providing a universal calibration and error correction method for multi-line-laser-sensor rotational scanning measurement systems.To address the challenges of complex sensor calibration procedures and workpiece placement eccentricity in online 3D geometric parameter measurement of train wheels,this study proposes a high-precision measurement system based on multiple line laser sensors,along with an error correction method.A multi-layer dynamic coordinate transformation model is developed to accurately map sensor data to the wheel′s 3D geometric information without being constrained by placement eccentricity.A stepwise calibration strategy is employed,using cube,cylinder,and profiled rotary calibration blocks to sequentially calibrate the installation pose and position parameters of the sensors.A pose fine-tuning mechanism is further implemented to achieve coplanar calibration of multiple sensors,overcoming coplanarity challenge caused by assembly errors in large-scale scanning systems.To address wheel placement eccentricity,an eccentricity error compensation method based on dynamic polar coordinate correction is introduced.By computing the axis offset in real-time and tracking the workpiece axis trajectory,radial dimension measurement errors are significantly reduced,overcoming the limitations of traditional mechanical centering under special operating conditions.Experimental results show that the system achieves an absolute measurement error is less than±0.069 mm,a repeatability standard deviation below 0.049 mm,and a fluctuation range of radial dimension errors after correction reduced to within 0.170 mm,meeting industrial-grade precision measurement requirements.In practical engineering applications,the maximum relative error between the system′s measurement results for complex geometric features of a 915KKD-type wheel and reference values obtained by a laser tracker is less than 0.135%,confirming the system′s reliability and engineering applicability.Beyond train wheels,the system can be extended to other rotary workpieces for 3D precision measurements,providing a universal calibration and error correction solution for multi-line-laser-sensor rotational scanning measurement systems.
作者
李欣飞
鄢然
夏磊
赵青
张凯飞
Li Xinfei;Yan Ran;Xia Lei;Zhao Qing;Zhang Kaifei(College of Mechanical Engineering,Chongqing University of Technology,Chongqing 400054,China)
出处
《仪器仪表学报》
北大核心
2025年第6期71-82,共12页
Chinese Journal of Scientific Instrument
基金
国家自然科学基金(52305247)项目资助。
关键词
线激光传感器
位姿标定
误差修正
火车轮测量
三维测量
line laser sensor
pose calibration
error correction
train wheel measurement
3D measurement
