Rapid and accurate rotor wing measurement method

Abstract

The invention discloses a rotor rapid and accurate measurement method, which is implemented by adopting a multi-module integrated multifunctional rotor measurement instrument, and comprises the following steps: firstly, based on a stable base body made of marble, carrying out rapid positioning and high-precision size measurement on a rotor root mounting hole by utilizing a root measurement module of the measurement instrument, and ensuring a clamping reference; secondly, the airfoil surface measurement module is moved to different preset measurement sections in the spanwise direction of the rotor along a preset sliding rail of the base body, airfoil profile torsion angle and chord length data of the sections are synchronously obtained through a torsion angle sensor and a chord length sensor integrated with the airfoil surface measurement module, and the rotor does not need to be repeatedly adjusted; and finally, the data acquisition and processing module receives and integrates multi-source measurement data from the root and airfoil modules in real time, automatically calculates key parameters, and generates a standardized detection report. According to the method, the rotor root size, airfoil profile torsion angle distribution and chord length distribution are rapidly and accurately measured, the measurement precision and efficiency are greatly improved, and the method is particularly suitable for batch quality detection and research and development analysis of rotors.

Description

Technical Field

[0001] This application belongs to the field of aerospace and UAV component measurement technology, specifically relating to a method for rapid and accurate measurement of core geometric parameters of rotors (especially helicopter and UAV rotors). Background Technology

[0002] The rotor provides all or most of the lift and propulsion / control force for helicopters and multirotor aircraft. Essentially, it's a core system integrating flight control surfaces and a lift / propulsion device, equivalent to a "rotating wing" plus "rotating control surfaces." Therefore, the accuracy of its geometric parameters, especially the blade twist angle (blade angle) distribution from root to tip, chord length distribution, and the derived pitch distribution, directly determines the aircraft's aerodynamic efficiency, stability, and safety. Accurate and efficient measurement of these geometric parameters is crucial in rotor manufacturing, quality inspection, and reverse engineering.

[0003] Traditional rotor measurement methods primarily rely on manual tools, such as micrometers and calipers to measure the dimensions of the root mounting holes and chord lengths, and graduated gauges or specialized templates to measure the blade angles at various cross-sections. This approach has significant drawbacks: First, it is functionally fragmented; different parameters require different tools, involving repeated clamping and positioning, making the operation cumbersome and a single measurement typically taking over 15 minutes, failing to meet the high-efficiency quality inspection requirements of mass production. Second, accuracy is greatly affected by human factors, especially in the positioning of the root mounting holes and the precise alignment of each measurement cross-section, which easily introduces errors, leading to repeatability errors in critical dimensions potentially exceeding ±0.5%, resulting in poor data consistency. Finally, measurement data is fragmented, requiring manual recording and subsequent integration, making it difficult to automatically generate standardized reports for direct analysis and traceability, resulting in low efficiency and a high risk of errors.

[0004] To overcome the shortcomings of traditional manual measurement, some automated measurement solutions have emerged in existing technologies. For example, some devices focus on the dynamic balancing or conicity measurement of rotors, such as using stereo vision technology to measure the spatial positional relationship of blades in a rotating state (e.g., rotor conicity). These methods mainly address the dynamic and macroscopic measurement of overall aircraft performance parameters, rather than performing high-precision, full-size scanning measurements of the microscopic and static geometric shape of the blades themselves (e.g., twist angle, chord length). Another example is the multifunctional propeller measuring instrument and method disclosed in patent CN112078827B, which provides a solution for measuring fixed-wing aircraft propellers. Its technical solution is designed for the characteristics of symmetrical, small-sized, and multi-blade synchronous measurement of propellers. However, its clamping method (fixed as a whole by the rotor hub) and measurement path (multi-axis platform driving sensor movement) are not directly applicable to rotor measurement scenarios where one end is fixed, slender, and requires point-by-point scanning starting from the root reference. For example, the applicant's patent CN12988290U discloses a multi-functional rotor measuring instrument, but it only discloses the structure of the measuring instrument and does not disclose the specific measurement method, which is not conducive to efficient measurement.

[0005] Therefore, existing technologies lack a method that can achieve integrated, automated, high-precision, and rapid measurement of rotor structural characteristics, from root reference to airfoil profile, and from key installation dimensions to aerodynamic parameters. Summary of the Invention

[0006] Based on the deficiencies of the prior art mentioned in the background section, the purpose of this application is to overcome these shortcomings and provide a rapid and accurate rotor measurement method. This method aims to solve the problems of low efficiency, poor accuracy, and inconsistent data in traditional manual measurement, as well as the poor adaptability of existing automated equipment to rotor measurement requirements. This application achieves rapid, accurate, and integrated measurement of core geometric parameters such as rotor root dimensions, spanwise section twist angles, and chord lengths through a logically rigorous integrated measurement process, and automatically generates standardized inspection reports.

[0007] To achieve the above objectives, the technical solution adopted in this application is: a rapid and accurate rotor measurement method, characterized by the use of a multi-module integrated multi-functional rotor measuring instrument, comprising the following steps: S1. Establish clamping reference: The root measurement and positioning unit accurately measures and clamps the rotor root mounting hole, taking the center of the mounting hole as the geometric reference origin, and accurately measures the key positioning dimensions of the rotor root. S2. Perform synchronous scanning measurement: Position the airfoil movement measurement unit to a preset measurement section along the span (length direction) of the rotor; synchronously collect airfoil twist angle and chord length data at each measurement section; S3. Generate an integrated report: The key positioning dimensions of the root measured in step S1 and the airfoil twist angle and chord length data of each section collected in step S2 are automatically integrated, calculated and correlated through the data center unit, and a standardized inspection report containing complete rotor geometric parameters, distribution curves and quality judgment is generated.

[0008] Furthermore, step S1 specifically includes: S1.1 The root of the rotor is fixed to the root measurement and positioning unit of the integrated multi-functional rotor measuring instrument by means of a positioning shaft and fasteners, to ensure that the rotor axis is parallel to the measurement reference direction; S1.2 Using the positioning slider of the root measurement and positioning unit and the high-precision micrometer integrated on the positioning slider, the distance from the center of the mounting hole to the rotor root reference edge (i.e., the rotor root plane) and its leading edge are measured respectively, thereby accurately obtaining the key positioning dimensions of the root and establishing a unique and accurate spatial reference for subsequent airfoil measurements.

[0009] Furthermore, in step S2, the wing movement measuring unit slides along a preset precision linear guide rail on the integrated multi-functional rotor measuring instrument base via its base, thereby quickly and smoothly realizing movement and precise positioning at different positions (different radius sections) along the rotor span.

[0010] Further, in step S2, the specific process of synchronously acquiring data at each measurement section is as follows: By adjusting the position of the airfoil movement measurement unit in three spatial directions (X, Y, Z) and the torsion angle around the axis, the measuring end of the chord length sensor (such as a high-precision caliper probe) can be simultaneously and accurately aligned with and slightly contact the leading and trailing edges of the airfoil at the current section of the rotor. At this time, the system synchronously records the chord length reading output by the chord length sensor and the torsion angle reading (i.e., torsion angle α) of the airfoil chord line relative to the horizontal reference plane output by the torsion angle sensor (such as a high-precision digital inclinometer).

[0011] Further, in step S2, the preset measurement cross-section covers the effective measurement area from the rotor root to the blade tip. Preferably, the positions of the multiple cross-sections are determined according to the effective radius R of the rotor in a standard proportion, for example including one or more of 0.2R, 0.3R, 0.4R, 0.5R, 0.6R, 0.7R, 0.8R, 0.9R, and 1.0R (blade tip), to ensure that the geometric features of the blade can be completely depicted.

[0012] Furthermore, in step S3, the automatic integration and calculation function of the data center unit includes: automatically calculating the local pitch H of each section according to the twist angle α of each measurement section and its distance (radius r) to the rotation center, based on the aviation industry standard pitch calculation formula H=2πrtanα, and generating a pitch distribution curve along the span.

[0013] Furthermore, to improve the reliability of the measurement results, a data verification step may be included before generating the final report in step S3: repeat the complete measurement process of steps S2 and S3 for the same rotor at least twice, and take the arithmetic average of the multiple measurement results to effectively eliminate accidental random errors.

[0014] Furthermore, the base of the integrated multi-functional rotor measuring instrument is preferably made of marble. Marble has high stability, low coefficient of thermal expansion, and excellent shock absorption performance, which can provide a long-term stable and deformation-free physical reference for the entire measurement system, fundamentally ensuring that the measurement accuracy is not affected by environmental micro-vibrations and deformations.

[0015] Compared with the prior art mentioned in the background section, the rotor rapid and accurate measurement method provided in this application has the following significant advantages: Significantly improved measurement accuracy: By using a highly stable marble substrate as a benchmark, combined with precise positioning of the root mounting holes and digital micrometry and sensing technology, the measurement error of core geometric parameters (such as mounting hole position and torsion angle) is controlled within ±0.01mm, which is more than 50 times more accurate than the traditional manual measurement method.

[0016] Measurement efficiency is significantly optimized: An integrated process of "single clamping, slide rail scanning, and multi-parameter synchronization" is adopted, seamlessly connecting root measurement with airfoil scanning. This replaces the traditional multi-tool, multi-step decentralized measurement method, reducing the complete measurement cycle of a single rotor from more than 15 minutes to less than 5 minutes, improving efficiency by more than 60%, making it particularly suitable for rapid full inspection in mass production lines.

[0017] High degree of automation and intelligence: The entire measurement process, from data acquisition, real-time processing, parameter calculation to report generation, is automatically completed by the central data center unit, achieving "report ready as soon as measurement is completed." This avoids errors caused by manual recording, sorting, and calculation, and the generated standard reports support electronic storage and traceability, greatly facilitating product quality control and R&D data analysis.

[0018] High standardization and repeatability of operations: The methods and procedures are standardized, with low reliance on operator experience. Unified clamping standards and automated scanning and measurement procedures ensure a high degree of consistency and comparability of measurement results from different personnel and different batches. Attached Figure Description

[0019] Figure 1 A schematic diagram of the rapid and accurate rotor measurement method of this application.

[0020] Figure 2 for Figure 1 A partial detailed view of the mid-root measurement and positioning unit (region I).

[0021] Figure 3 for Figure 1 A partial detailed view of the moving measurement unit (Area II) in the middle wing.

[0022] Figure 4 This is a detailed view of another twist angle of the wing movement measurement unit (area II).

[0023] Figure 5 This is a flowchart of the rapid and accurate measurement process for the rotor in this application.

[0024] The markings in the diagram are: 100 Base, 110 Guide rail, 120 Grating instrument; 200 Data center unit; 300 Root measurement and positioning unit, 310 Fixing plate, 311 Slide groove, 312 Leading edge slider, 313 Paddle root slider, 314 Micrometer head, 315 Positioning shaft, 316 Fastening nut; 400 Wing movement measurement unit, 410 Lifting platform, 420 Tilt seat, 430 Torsion angle measuring instrument, 440 Lateral movement seat, 450 Chord length measuring instrument, 460 Torsion angle adjustment knob, 470 Lifting adjustment knob; 500 Rotor blade. Detailed Implementation

[0025] The technical solution of this application will be clearly and completely described below with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0026] In the description of this application, it should be noted that the terms "center", "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to simplify the description of this application and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0028] The implementation methods of the technical solutions of this application will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0029] This embodiment uses the measurement of a single blade of the main rotor of a certain type of unmanned helicopter as an example to illustrate the implementation process of the method of this application in detail. The structure of the integrated multi-functional rotor measuring instrument used can be found in [reference needed]. Figures 1 to 5 .

[0030] Step 1: System preparation and rotor clamping, corresponding to step S1 in claim 1: Place the integrated multi-functional rotor measuring instrument in a horizontal, vibration-free working environment. First, clean the platform surface and guide rails. Then, as follows... Figure 2 and Figure 4 As shown, the rotor blade 5 under test is placed horizontally, with its root mounting hole aligned with the positioning shaft 314 on the root measurement and positioning unit 300, and secured with a fastening nut 315. Next, the positioning sliders on the fixing plate 310—the leading edge slider 312 and the root slider 313—are pushed to ensure close contact between the leading edge slider 312 and the root reference surface of the blade root. The micrometer heads 314 on each slider are adjusted, transmitting high-precision displacement signals to the data center 200. The software automatically records and calculates the precise distances from the center of the mounting hole to the root reference and the leading edge (e.g., 25.00 mm from the root and 15.50 mm from the leading edge). This step completes the precise reference positioning of the rotor, and all subsequent measurement data are based on this coordinate system.

[0031] Step 2: Airfoil section scanning measurement, corresponding to step S2 in claim 2: After clamping, the operator sets the measurement section in the control software. In this example, the measurement radius is set to 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, and 0.9 times the effective radius R of the blade (i.e., 0.3R to 0.9R).

[0032] Positioning: Manually push the longitudinal wing section moving measurement unit 400 to move it along the precision linear guide rail 110 on the base 100. The position of the longitudinal wing section moving measurement unit 400 is fed back in real time by the grating ruler 120. When the longitudinal wing section moving measurement unit 400 moves to the target radius position (e.g., 0.5R), it stops moving.

[0033] Correction and collection: such as Figure 3 and Figure 4As shown, the airfoil measuring device located on the airfoil movement measuring unit 400 begins operation. The lifting platform 470, tilting seat 420, and lateral moving seat 440 are adjusted to ensure the measuring surface of the torsion angle measuring instrument 430 is in contact with the airfoil chord. The two measuring jaws of the chord length measuring instrument 450 mounted on the torsion angle measuring instrument 430 are precisely aligned and gently clamped onto the leading and trailing edges of the current airfoil section. The chord length measuring instrument 450 measures the current chord length, e.g., C = 105.3 mm, and the torsion angle measuring instrument 430 measures the current torsion angle, e.g., α = 12.5°. Both sets of data are simultaneously acquired and transmitted to the data center 200.

[0034] Successive scanning: After completing the measurement of this section, release the chord length measuring instrument 450, move the longitudinal wing moving measuring unit 400 to the next preset section (such as 0.6R), and repeat the above alignment and acquisition process until all preset sections have been measured.

[0035] Step 3: Data processing and report generation, corresponding to step S3 in claim 3: After all cross-sectional data is collected, the central data center unit (Integrated Data Center 200) will automatically perform the following operations: Data integration: The root positioning dimensions obtained in step one are correlated with the radius r, twist angle α, and chord length C of all cross sections obtained in step two in a unified coordinate system.

[0036] Parameter calculation: For each measurement section, the local pitch is automatically calculated according to the formula H = 2πr * tanα. For example, when r = 0.5R = 800mm and α = 12.5°, the pitch H at that location is calculated.

[0037] Graphical and Judgment: The software automatically draws the "torsion angle-radius" distribution curve, "chord length-radius" distribution curve, and "pitch-radius" distribution curve, and allows input of design tolerance range. The software will automatically perform acceptance judgment and mark the points that exceed the tolerance.

[0038] Report Generation: Finally, the system generates a standardized test report in PDF format with one click. The report includes: basic rotor information, raw data tables for all measurement points, calculated parameter tables, the above distribution curves, and corresponding quality judgments for use in quality archiving or process analysis.

[0039] To verify the repeatability of the measurement results, the second and third steps can be repeated twice for the same blade. The software can average the torsion angle and chord length data from the three measurements, calculate the standard deviation, and finally generate a report based on the average value, thereby further eliminating random errors and ensuring the robustness and reliability of the data.

[0040] The rapid and accurate rotor measurement process described in this application can be found in [link to application]. Figure 5The specific implementation is as follows: After the preparation work, the rotor is clamped and the rotor hole measurement stage is entered. The size and position of the mounting hole are measured. After the data is determined to be valid, the wing measurement stage is entered. The wing twist angle and chord length are measured and the data is determined to be valid. After the data is valid, the data processing, analysis and organization work is carried out, and a measurement report is generated. The measurement work is completed.

[0041] The above description is merely a preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this application, based on the technical solution and application concept of this application, should be included within the scope of protection of this application.

[0042] The above description is merely a preferred embodiment of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application are included within the scope of protection of this application.

Claims

1. A method for rapid and accurate measurement of a rotor, characterized in that... The implementation using a multi-module integrated multi-functional rotor measurement instrument includes the following steps: S1. Establish clamping reference: The root measurement and positioning unit accurately measures and clamps the rotor root mounting hole, and uses the center of the mounting hole as a reference to measure the key positioning dimensions of the rotor root. S2. Perform synchronous scanning measurement: Position the airfoil movement measurement unit to multiple preset measurement sections along the spanwise direction of the rotor; synchronously collect airfoil twist angle and chord length data at each measurement section. S3. Generate an integrated report: The root key dimensions measured in step S1 and the airfoil twist angle and chord length data collected in step S2 are automatically integrated, calculated and correlated through the data center unit, and a standardized inspection report containing complete rotor geometric parameters and quality judgment is generated.

2. The rapid and accurate rotor measurement method according to claim 1, characterized in that, Step S1 specifically includes: S1.1 The root of the rotor is fixed to the root measurement and positioning unit of the integrated multi-functional rotor measuring instrument by means of a positioning shaft and fasteners, to ensure that the rotor axis is parallel to the measurement reference direction; S1.2 Using a positioning slider and a micrometer head, measure the distance from the center of the mounting hole to the reference edge and leading edge of the rotor root to obtain the key positioning dimensions of the root.

3. The rapid and accurate rotor measurement method according to claim 1, characterized in that, In step S2, the wing movement measuring unit moves and positions itself along the spanwise direction of the rotor by sliding along a pre-set linear guide rail on the integrated multi-functional rotor measuring instrument base.

4. The rapid and accurate rotor measurement method according to claim 1, characterized in that, In step S2, the specific process of synchronously collecting airfoil twist angle and chord length data at each measurement section is as follows: by adjusting the spatial pose of the airfoil moving measurement unit, the measuring end of the chord length sensor is simultaneously aligned with and in contact with the leading edge and trailing edge of the rotor section airfoil, and at this time, the chord length reading of the chord length sensor and the twist angle reading of the twist angle sensor are recorded.

5. The rapid and accurate rotor measurement method according to claim 1, characterized in that, In step S2, the preset measurement cross section includes multiple cross sections from the rotor root to the blade tip. The positions of the multiple cross sections are determined proportionally according to the effective radius R of the rotor, including one or more of 0.2R, 0.3R, 0.4R, 0.5R, 0.6R, 0.7R, 0.8R, 0.9R, and 1.0R.

6. The rapid and accurate rotor measurement method according to claim 1, characterized in that, In step S3, the automatic integration and calculation of the data center unit includes: automatically calculating the local pitch H of each section according to the formula H=2πrtanα based on the torsion angle α of each measurement section and its distance r from the rotation center, and generating a pitch distribution map along the span.

7. The rapid and accurate rotor measurement method according to claim 1, characterized in that, Before generating the standardized test report, step S3 includes a data verification step: repeating the complete measurement process of steps S2 and S3 on the same rotor at least twice, and averaging the multiple measurement results to eliminate random errors.

8. The rapid and accurate rotor measurement method according to claim 1, characterized in that, The base of the integrated multi-functional rotor measuring instrument is made of marble.

9. The rapid and accurate measurement method for a rotor according to any one of claims 1 to 8, characterized in that, This method is applied to the mass production quality inspection process of rotor products, and the standardized inspection report is used to determine whether the rotor products are qualified.

10. The method for rapid and accurate measurement of a rotor according to any one of claims 1 to 8, characterized in that, This method is applied to the research and development design and reverse engineering analysis process of rotors. The geometric parameter distribution data in the standardized test report is used to compare with the design values ​​or to establish a three-dimensional digital model.

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