A Laser-Based Measuring System for Online Quality Control of Car Engine Block

For online quality control of car engine production, pneumatic measurement instrument plays an unshakeable role in measuring diameters inside engine block because of its portability and high-accuracy. To the limitation of its measuring principle, however, the working space between the pneumatic device and measured surface is too small to require manual operation. This lowers the measuring efficiency and becomes an obstacle to perform automatic measurement. In this article, a high-speed, automatic measuring system is proposed to take the place of pneumatic devices by using a laser-based measuring unit. The measuring unit is considered as a set of several measuring modules, where each of them acts like a single bore gauge and is made of four laser triangulation sensors (LTSs), which are installed on different positions and in opposite directions. The spatial relationship among these LTSs was calibrated before measurements. Sampling points from measured shaft holes can be collected by the measuring unit. A unified mathematical model was established for both calibration and measurement. Based on the established model, the relative pose between the measuring unit and measured workpiece does not impact the measuring accuracy. This frees the measuring unit from accurate positioning or adjustment, and makes it possible to realize fast and automatic measurement. The proposed system and method were finally validated by experiments.

[1]  Martyn Hill,et al.  A comparison of precision optical displacement sensors for the 3D measurement of complex surface profiles , 2008 .

[2]  Jean-François Brouckaert,et al.  Assessment of Unsteady Pressure Measurement Uncertainty—Part I: Single Sensor Probe , 2016 .

[3]  E. Peiner,et al.  Slender Tactile Sensor for Contour and Roughness Measurements Within Deep and Narrow Holes , 2008, IEEE Sensors Journal.

[4]  Robert Schmitt,et al.  On-the-fly calibration of linear and rotary axes of machine tools and CMMs using a tracking interferometer , 2009 .

[5]  Hiroshi Kawamata,et al.  On-machine non-contact dimension-measurement system with laser displacement sensor for vane-tip machining of RFQs , 2012 .

[6]  Fumin Zhang,et al.  An Automated Inner Dimensional Measurement System Based on a Laser Displacement Sensor for Long-Stepped Pipes , 2012, Sensors.

[7]  D. Gweon,et al.  High-speed 3-D measurement with a large field of view based on direct-view confocal microscope with an electrically tunable lens. , 2016, Optics express.

[8]  Kunpeng Feng,et al.  A Twin Fiber Bragg Grating Probe for the Dimensional Measurement of Microholes , 2014, IEEE Photonics Technology Letters.

[9]  Adam Gąska,et al.  Validation model for coordinate measuring methods based on the concept of statistical consistency control , 2016 .

[10]  Richard K. Leach,et al.  Performance Assessment of a New Variable Stiffness Probing System for Micro-CMMs , 2016, Sensors.

[11]  Arthur C. Sanderson,et al.  JADE: Adaptive Differential Evolution With Optional External Archive , 2009, IEEE Transactions on Evolutionary Computation.

[12]  G. Mansour,et al.  A developed algorithm for simulation of blades to reduce the measurement points and time on coordinate measuring machine (CMM) , 2014 .

[13]  Eduardo Cuesta,et al.  Sensor Prototype to Evaluate the Contact Force in Measuring with Coordinate Measuring Arms , 2015, Sensors.

[14]  Zhe Chen,et al.  Fast Measurement and Reconstruction of Large Workpieces with Freeform Surfaces by Combining Local Scanning and Global Position Data , 2015, Sensors.

[15]  Rudolf Seethaler,et al.  Novel Method for Interstory Drift Measurement of Building Frames Using Laser-Displacement Sensors , 2016 .

[16]  Rainer Storn,et al.  Differential Evolution – A Simple and Efficient Heuristic for global Optimization over Continuous Spaces , 1997, J. Glob. Optim..

[17]  Peng Wang,et al.  High-speed measurement algorithm for the position of holes in a large plane , 2012 .

[18]  R. Storn,et al.  Differential Evolution - A simple and efficient adaptive scheme for global optimization over continuous spaces , 2004 .

[19]  Petr Zavyalov.  3D Hole Inspection Using Lens with High Field Curvature , 2015 .

[20]  Jean-François Brouckaert,et al.  Assessment of Unsteady Pressure Measurement Uncertainty—Part II: Virtual Three-Hole Probe , 2016 .

[21]  Antonin Miks,et al.  Analysis of imaging for laser triangulation sensors under Scheimpflug rule. , 2013, Optics express.

[22]  Mohammed N. Islam,et al.  Optical probe for porosity defect detection on inner diameter surfaces of machined bores , 2010 .

[23]  Eduardo Cuesta,et al.  Analysis of laser scanning and strategies for dimensional and geometrical control , 2010 .

[24]  Youngchul Bae,et al.  An Improved Measurement Method for the Strength of Radiation of Reflective Beam in an Industrial Optical Sensor Based on Laser Displacement Meter , 2016, Sensors.

[25]  Jung Chul Lee,et al.  Spindle error motion measurement of a large precision roll lathe , 2012 .

[26]  Feng Yuan,et al.  An automatic measuring method and system using laser triangulation scanning for the parameters of a screw thread , 2014 .