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Error measurement and assemble error correction of a 3D-step-gauge

MAO Xinyong, LI Bin, SHI Hanmin, LIU Hongqi, LI Xi, LI Peigen

《机械工程前沿（英文）》 2007年第2卷第4期页码 388-393 doi: 10.1007/s11465-007-0067-x

摘要： A new artifact called 3D-step-gauge consisting of a pyramid array and a compound, is proposed to calculate geometrical errors for machine tools. Only one point on each profile of the pyramid in the array is probed, and its center coordinate can be calculated. Then, the intervals of the pyramids can be transfered a length standard to measure errors. Considering the differences in the structural parameters and the location of the pyramids, a volumetric error measurement method of discrete points is presented. Furthermore, the location errors between the calibration state and the measurement state are studied and their influences on the accuracy of the position measurement are investigated on an actual machine tool. The 3D-step-gauge was tested on an actual machine tool and the measurement result shows quick assembly, convenient measurement, and high accuracy.

关键词： volumetric pyramid assembly accuracy calibration

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测量与信息技术

张国雄

《中国工程科学》 2000年第2卷第3期页码 62-66

摘要：

测量是获取信息的重要手段。科学研究、生产、高科技发展都离不开测量。测量技术发展的重要特点是它与信息技术的融合，这是提高测量精度、在线和动态测量、复杂参数和复杂环境下测量、智能测量的需要。这一融合贯穿始终，它包括信号调制与解调、采样与重构、信号融合、数据压缩、滤波、信号变换、时间序列分析、谱分析、数据拟合与建模、模式识别、神经网络、仿真与虚拟、误差分离、误差补偿、冗余技术、决策与智能技术等，它们互相支持。文章通过三坐标测量机误差补偿、圆度和轴系误差测量，以及大型工程的柔性坐标测量系统，介绍其在提高测量精度、优化、自标定、丢失信息自恢复、系统重组等方面的作用及其关键技术。

关键词：测量信息技术误差补偿建模冗余技术误差分离

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Review of self-referenced measurement algorithms: Bridging lateral shearing interferometry and multi-probeerror separation

Dede ZHAI, Shanyong CHEN, Ziqiang YIN, Shengyi LI

《机械工程前沿（英文）》 2017年第12卷第2期页码 143-157 doi: 10.1007/s11465-017-0432-3

摘要：

With the development of new materials and ultra-precision processing technology, the sizes of measured objects increase, and the requirements for machining accuracy and surface quality become more exacting. The traditional measurement method based on reference datum is inadequate for measuring a high-precision object when the quality of the reference datum is approximately within the same order as that of the object. Self-referenced measurement techniques provide an effective means when the direct reference-based method cannot satisfy the required measurement or calibration accuracy. This paper discusses the reconstruction algorithms for self-referenced measurement and connects lateral shearing interferometry and multi-probe error separation. In lateral shearing interferometry, the reconstruction algorithms are generally categorized into modal or zonal methods. The multi-probe error separation techniques for straightness measurement are broadly divided into two-point and three-point methods. The common features of the lateral shearing interferometry method and the multi-probe error separation method are identified. We conclude that the reconstruction principle in lateral shearing interferometry is similar to the two-point method in error separation on the condition that no yaw error exists. This similarity may provide a basis or inspiration for the development of both classes of methods.

关键词： self-referenced measurement lateral shearing interferometry multi-probe error separation surface metrology

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Measurement and analysis of typical motion error traces from a circular test

LI Xiaoli, LIU Huanlao

《机械工程前沿（英文）》 2008年第3卷第2期页码 146-150 doi: 10.1007/s11465-008-0033-2

摘要： The circular test provides a rapid and efficient way of measuring the contouring accuracy of a machine tool. To get the actual point coordinate in the work plane, an improved measurement instrument - a new ball bar test system - is presented in this paper to identify both the radial error and the rotation angle error when the machine is manipulated to move in circular traces. Based on the measured circular error, a combination of Fourier components is chosen to represent the systematic form error that fluctuates in the radial direction. The typical motion errors represented by the corresponding Fourier components can thus be identified. The values for machine compensation can be calculated and adjusted until the desired results are achieved.

关键词： machine compensation direction combination desired efficient

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Evaluation of measurement uncertainty of the high-speed variable-slit system based on the Monte Carlo

Yin ZHANG, Jianwei WU, Kunpeng XING, Zhongpu WEN, Jiubin TAN

《机械工程前沿（英文）》 2020年第15卷第4期页码 517-537 doi: 10.1007/s11465-020-0589-z

摘要： This paper presents a dynamic and static error transfer model and uncertainty evaluation method for a high-speed variable-slit system based on a two-dimensional orthogonal double-layer air-floating guide rail structure. The motion accuracy of the scanning blade is affected by both the moving component it is attached to and the moving component of the following blade during high-speed motion. First, an error transfer model of the high-speed variable-slit system is established, and the influence coefficients are calculated for each source of error associated with the accuracy of the blade motion. Then, the maximum range of each error source is determined by simulation and experiment. Finally, the uncertainty of the blade displacement measurement is evaluated using the Monte Carlo method. The proposed model can evaluate the performance of the complex mechanical system and be used to guide the design.

关键词： air-floating guide rail error transfer model driving and following structure dynamic error uncertainty evaluation Monte Carlo method

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Study on the measurement of temperature field using laser holographic interferometry

Jinrong ZHU, Suyi HUANG, Wei LV, Huaichun ZHOU

《能源前沿（英文）》 2011年第5卷第1期页码 120-124 doi: 10.1007/s11708-010-0107-9

摘要： The temperature field of an axisymmetric ethylene diffusion flame is measured using laser holographic interferometry. Temperature field inversion is completed with the aid of components distribution divided from numerical simulation of combustion and air components assumption. Error analysis of key steps is conducted using the theoretical formula of interference temperature measurement and characteristic structure of fringes obtained from optical simulation. Based on the calculation and analysis, air components assumption will not cause significant error in the low temperature region but will result in high error in the high temperature region. Moreover, the small error in environmental temperature measurement transfer to a high temperature range will expand more than tenfold. Results of temperature measurement using air components assumption relative to combustion simulation require the greatest amendment amounting to seven percent.

关键词： temperature field flame error analysis holographic interferometry

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Chord error constraint based integrated control strategy for contour error compensation

Tie ZHANG, Caicheng WU, Yanbiao ZOU

《机械工程前沿（英文）》 2020年第15卷第4期页码 645-658 doi: 10.1007/s11465-020-0601-7

摘要： As the traditional cross-coupling control method cannot meet the requirements for tracking accuracy and contour control accuracy in large curvature positions, an integrated control strategy of cross-coupling contour error compensation based on chord error constraint, which consists of a cross-coupling controller and an improved position error compensator, is proposed. To reduce the contour error, a PI-type cross-coupling controller is designed, with its stability being analyzed by using the contour error transfer function. Moreover, a feed rate regulator based on the chord error constraint is proposed, which performs speed planning with the maximum feed rate allowed by the large curvature position as the constraint condition, so as to meet the requirements of large curvature positions for the chord error. Besides, an improved position error compensation method is further presented by combining the feed rate regulator with the position error compensator, which improves the tracking accuracy via the advance compensation of tracking error. The biaxial experimental results of non-uniform rational B-splines curves indicate that the proposed integrated control strategy can significantly improve the tracking and contour control accuracy in biaxial contour following tasks.

关键词： cross-coupling controller contour error tracking error position error compensator feed rate regulator

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一种针对测试误差、参数误差和负荷突变故障分析的多功能动态状态估计器 Article

Mehdi AHMADI JIRDEHI,Reza HEMMATI,Vahid ABBASI,Hedayat SABOORI

《信息与电子工程前沿（英文）》 2016年第17卷第11期页码 1218-1227 doi: 10.1631/FITEE.1500301

摘要：本文提出了一种基于卡尔曼滤波理论的动态状态估计新算法，可有效探测、识别并校正电力系统中的测试误差和支路参数误差。同时，该算法亦可成功探测和识别电力系统中的负荷突变。该方法在每段取样时间内，采用三种归一化向量对误差进行处理，包括归一化测量残差，归一化拉格朗日乘子，以及归一化新息向量。在IEEE14节点测试系统上对所提出的算法进行了可行性和效能验证，并通过对数值结果的呈示和讨论，说明了该方法的精确度。

关键词：动态状态估计器；卡尔曼滤波；测试误差；支路参数误差；负荷突变

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立体偏转测量系统几何参数的性能分析与评价 Article

徐永佳, 高峰, 蒋向前

《工程（英文）》 2018年第4卷第6期页码 806-815 doi: 10.1016/j.eng.2018.10.007

摘要：

本文提出了一种新颖的几何参数分析方法，以提高立体偏转系统的测量精度。立体偏转测量可用于获得自由曲面的三维形貌信息。基于立体偏转测量的测量系统通常由条纹显示屏、主相机和参考相机组成。立体偏转测量系统组件的布置对于实现高精度测量十分重要。本文分析和评估了立体偏转测量系统的4个几何参数：主相机与被测物体表面之间的距离、主相机光线与被测表面法线之间的角度、条纹显示屏与被测物体之间的距离，以及主相机和参考相机之间的角度。本文通过模拟和实验数据对这些几何参数对测量精度的影响进行了验证。实验结果证实了这些参数对测量精度的影响。基于本文所提出的分析方法，一个立体偏转系统被搭建并且被用于测量一个标准的凹面镜。通过与凹面镜的给定表面参数进行比较，该系统的全局测量精度可达154.2 nm。

关键词：光学测量误差分析立体偏转测量三维形貌测量性能评估模拟

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Kinematic error separation on five-axis NC machine tool based on telescoping double ball bar

Min WANG, Jianzhong HU, Tao ZAN

《机械工程前沿（英文）》 2010年第5卷第4期页码 431-437 doi: 10.1007/s11465-010-0110-1

摘要： The theory and algorithm of the homogeneous transformation matrix (HTM) method are applied in establishing the kinematic error model of five-axis machining tool with two-axis turntable. Based on this model, a new method for the kinematic error separation in five-axis numerical control (NC) machining tool is proposed. In this study, three types of simultaneous three-axis control motions are designed for each rotary axis to identify the deviations. In the measurement, two translational axes and one rotary axis are simultaneously controlled to keep a constant distance between the tool and the worktable. Telescoping double ball bar is used to measure the relative distance between the spindle and the worktable in the motion of NC machining tool. Finally, the value measured by telescoping double ball bar is substituted into the model to obtain kinematic error of NC machining tool. Comparison has confirmed that the proposed method is high precision and can be applied to effectively and conveniently measure the five-axis machining tool.

关键词： error modeling error separation telescoping double ball bar five-axis numerical control (NC) machining tool

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Robust ensemble of metamodels based on the hybrid error measure

《机械工程前沿（英文）》 2021年第16卷第3期页码 623-634 doi: 10.1007/s11465-021-0641-7

摘要： Metamodels have been widely used as an alternative for expensive physical experiments or complex, time-consuming computational simulations to provide a fast but accurate analysis. However, challenge remains in the prior determination of the most suitable metamodel for a particular case because of the lack of information about the actual behavior of a system. In addition, existing studies on metamodels have largely restricted on solving deterministic problems (e.g., data from finite element models), whereas some real-life engineering problems (e.g., data from physical experiment) are stochastic problems with noisy data. In this work, a robust ensemble of metamodels (EMs) is proposed by combining three regression stand-alone metamodels in a weighted sum form. The weight factor is adaptively determined according to the hybrid error metric, which combines global and local error measures to improve the accuracy of the EMs. Furthermore, three typical individual metamodels that can filter noise are selected to construct the EMs to extend their application in practical engineering problems. Three well-known benchmark problems with different levels of noise and three engineering problems are used to verify the effectiveness of the proposed EMs. Results show that the proposed EMs have higher accuracy and robustness than the individual metamodels and other typical EMs in major cases.

关键词： metamodel ensemble of metamodels hybrid error measure stochastic problem

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density measurement for plastic injection molding via ultrasonic technology

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0714-2

摘要： Density variation during the injection molding process directly reflects the state of plastic melt and contains valuable information for process monitoring and optimization. Therefore, in-situ density measurement is of great interest and has significant application value. The existing methods, such as pressure−volume−temperature (PVT) method, have the shortages of time-delay and high cost of sensors. This study is the first to propose an in-situ density measurement method using ultrasonic technology. The analyses of the time-domain and frequency-domain signals are combined in the proposed method. The ultrasonic velocity is obtained from the time-domain signals, and the acoustic impedance is computed through a full-spectral analysis of the frequency-domain signals. Experiments with different process conditions are conducted, including different melt temperature, injection speed, material, and mold structure. Results show that the proposed method has good agreement with the PVT method. The proposed method has the advantages of in-situ measurement, non-destructive, high accuracy, low cost, and is of great application value for the injection molding industry.

关键词： ultrasonic measurement melt density in-situ measurement injection molding

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Inverse Gaussian process-based corrosion growth modeling and its application in the reliability analysis for energy pipelines

Hao QIN, Shenwei ZHANG, Wenxing ZHOU

《结构与土木工程前沿（英文）》 2013年第7卷第3期页码 276-287 doi: 10.1007/s11709-013-0207-9

摘要： This paper describes an inverse Gaussian process-based model to characterize the growth of metal-loss corrosion defects on energy pipelines. The model parameters are evaluated using the Bayesian methodology by combining the inspection data obtained from multiple inspections with the prior distributions. The Markov Chain Monte Carlo (MCMC) simulation techniques are employed to numerically evaluate the posterior marginal distribution of each individual parameter. The measurement errors associated with the ILI tools are considered in the Bayesian inference. The application of the growth model is illustrated using an example involving real inspection data collected from an in-service pipeline in Alberta, Canada. The results indicate that the model in general can predict the growth of corrosion defects reasonably well. Parametric analyses associated with the growth model as well as reliability assessment of the pipeline based on the growth model are also included in the example. The proposed model can be used to facilitate the development and application of reliability-based pipeline corrosion management.

关键词： pipeline metal-loss corrosion inverse Gaussian process measurement error hierarchical Bayesian Markov Chain Monte Carlo (MCMC)

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具有新概念的运动误差及形状误差的分离法——虚位数据法

洪迈生,李自军,苏恒,叶飞帆

《中国工程科学》 2002年第4卷第10期页码 48-51

摘要：

提出了一种基于信号重建的虚位数据法，用此方法，可以按需要任意选择只分离形状误差或只分离运动误差，或者任意安排分离这两类误差的先后顺序，而不必变更传统的形状误差检测-分离系统，方式灵活，使用方便。

关键词：虚位数据信号重建形状误差运动误差误差分离技术

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Dependence of error sensitivity of frequency on bias voltage in force-balanced micro accelerometer

Lili CHEN, Wu ZHOU

《机械工程前沿（英文）》 2013年第8卷第2期页码 146-149 doi: 10.1007/s11465-013-0260-z

摘要：

To predict more precisely the frequency of force-balanced micro accelerometer with different bias voltages, the effects of bias voltages on error sensitivity of frequency is studied. The resonance frequency of accelerometer under closed loop control is derived according to its operation principle, and its error sensitivity is derived and analyzed under over etching structure according to the characteristics of Deep Reaction Ion Etching (DRIE). Based on the theoretical results, micro accelerometer is fabricated and tested to study the influences of AC bias voltage and DC bias voltage on sensitivity, respectively. Experimental results indicate that the relative errors between test data and theory data are less than 7%, and the fluctuating value of error sensitivity under the range of voltage adjustment is less than 0.01 μm . It is concluded that the error sensitivity with designed parameters of structure, circuit and process error can be used to predict the frequency of accelerometer with no need to consider the influence of bias voltage.

关键词： Micro-Electro-Mechanical Systems (MEMS) micro accelerometer force-balanced micro accelerometer frequency error sensitivity