A synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement

Abstract

A synchronous real-time rudder deflection angle detection system based on laser and CCD image measurement is disclosed, involving a rudder surface angle measurement device to address the problems of poor measurement accuracy and low detection efficiency in existing detection systems. This novel coaxial laser sensor is used for non-contact real-time measurement of the outer surface of the cylinder under test, acquiring first image data of the outer surface; four sets of rudder surface laser sensors are used for non-contact real-time measurement of the four rudder surfaces of the test object, acquiring second image data of the four rudder surfaces; a CCD camera is used to acquire images of the interior of the cylinder under test, acquiring third image data of the interior; a data processing unit is used to calculate the coaxiality of the cylinder under test based on the first image data; calculate the rudder deflection angle of the rudder surface based on the second image data; and calculate the rudder deflection angle of the cylinder under test based on the third image data. The beneficial effects are improved measurement accuracy and detection efficiency.

Description

Technical Field

[0001] This utility model relates to a rudder surface angle measuring device. Background Technology

[0002] In the aerospace field, aerodynamic and thrust-vectoring composite control systems are widely used due to their ability to achieve high-precision control of flight attitude. These systems typically consist of aerodynamic control surfaces and gas turbine control surfaces, which work together to adjust the aircraft's attitude. During final assembly, the zero-position adjustment and assembly accuracy between the aerodynamic and gas turbine control surfaces are crucial, directly affecting the response speed, control accuracy, and overall reliability of the flight control system. Deviations in the zero-position of the control surfaces can lead to attitude instability, reduced control efficiency, and even serious safety accidents during flight.

[0003] However, existing methods for measuring rudder deflection angle mainly rely on contact measuring tools (such as mechanical protractors, electronic inclinometers, or contact displacement sensors) or manual visual calibration. These methods have the following significant drawbacks:

[0004] Limited measurement accuracy: Contact measuring tools are easily affected by human error, mechanical wear and environmental temperature changes, making it difficult to meet the stringent requirements of modern aerospace for rudder deflection angle measurement accuracy.

[0005] Unable to achieve synchronous real-time measurement: Existing measurement methods usually require measuring each control surface one by one, which cannot achieve synchronous real-time measurement of multiple control surfaces (such as aerodynamic control surfaces and gas control surfaces), resulting in low assembly efficiency and difficulty in capturing the real-time deflection state of the control surfaces under dynamic conditions.

[0006] Contact measurement introduces additional errors: Contact sensors or gauges may apply additional torque to the control surface during the measurement process, causing slight elastic deformation of the control surface, thereby introducing measurement errors, and may even cause potential damage to the precision control surface.

[0007] Therefore, there is an urgent need for a rudder deflection detection system that can measure the aerodynamic and gas-powered rudder angles in a high-precision, non-contact, synchronous, and real-time manner, in order to solve the problems of insufficient accuracy, low efficiency, and limited functionality of existing detection systems, thereby meeting the urgent needs of aerodynamic and thrust-vector composite rudder systems for high-precision assembly and reliability verification. Utility Model Content

[0008] The purpose of this invention is to solve the problems of poor measurement accuracy and low detection efficiency in existing detection systems, and to propose a synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement.

[0009] The present invention provides a synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement, comprising a CCD camera, a laser sensor group, and a data processing unit.

[0010] The laser sensor group includes a coaxial laser sensor and four sets of control surface laser sensors; the coaxial laser sensor is used to perform non-contact real-time measurement of the outer surface of the cylinder of the object under test and acquire the first image data of the outer surface of the cylinder; the four sets of control surface laser sensors are used to perform non-contact real-time measurement of the four control surfaces of the object under test and acquire the second image data of the four control surfaces.

[0011] The CCD camera is set at the tail of the object under test and is used to acquire images of the inside of the cylinder of the object under test and obtain third image data of the inside of the cylinder.

[0012] The data processing unit is used to receive first image data, second image data, and third image data, and calculate the coaxiality of the test object cylinder based on the first image data. Based on the coaxiality of the cylinder, it obtains the actual central axis position and attitude of the test object cylinder, and uses the actual central axis of the test object cylinder as the reference axis for the rudder deflection angle of the rudder surface and the rudder deflection angle of the cylinder. Based on the second image data and the coaxiality of the cylinder, it calculates the rudder deflection angle of the test object rudder surface. Based on the third image data and the coaxiality of the cylinder, it calculates the rudder deflection angle of the test object cylinder.

[0013] Furthermore, it also includes positioning brackets;

[0014] The positioning bracket includes a base plate, a first load-bearing plate, a second load-bearing plate, and a rudder surface fixing frame;

[0015] The first load-bearing plate, the second load-bearing plate, and the rudder surface fixing frame are all sequentially arranged on the base plate along the length of the base plate, with the first load-bearing plate located at the head of the object to be tested and the rudder surface fixing frame located at the rudder surface of the object to be tested.

[0016] The first load-bearing plate is provided with a first hydraulic adjustment mechanism on its side wall, and the second load-bearing plate is provided with a second hydraulic adjustment mechanism at its bottom. The central axis of the test cylinder is adjusted by the first hydraulic adjustment mechanism and the second hydraulic adjustment mechanism so that the central axis of the cylinder coincides with the optical axis of the CCD camera.

[0017] The coaxial laser sensor and the four sets of control surface laser sensors are all fixed inside the control surface fixing frame.

[0018] Furthermore, the positioning bracket also includes an auxiliary plate;

[0019] The auxiliary plate is fixed to the base plate and is located at the tail of the object to be tested;

[0020] The CCD camera is mounted on the front of the auxiliary plate.

[0021] Furthermore, this also includes displays;

[0022] The display signal input terminal of the display is connected to the display signal output terminal of the data processing unit; and the display is fixed on the top of the auxiliary board.

[0023] Furthermore, the field of view of the control surface laser sensor is greater than 96 mm × 96 mm, and the ranging accuracy of the control surface laser sensor is 0.1 mm.

[0024] Furthermore, the field of view of the coaxial laser sensor is greater than 96 mm × 96 mm, and the ranging accuracy of the rudder surface laser sensor is 0.1 mm.

[0025] Furthermore, the data processing unit employs an FPGA chip;

[0026] The operating temperature range of the FPGA chip is 5℃~35℃; the storage temperature range of the FPGA chip is -10℃~+40℃; the relative humidity range of the FPGA chip is 20%~80%; the power supply parameters of the FPGA chip are 5V, 10A.

[0027] Compared with the prior art, the present invention has the following advantages:

[0028] This invention integrates multiple sets of laser sensors, a CCD camera, and a data processing unit to achieve synchronous, real-time, non-contact, and high-precision measurement of the deflection angle of aerodynamic and gas turbine rudders. Its self-testing function improves the system's measurement accuracy and testing efficiency. Multiple test modes and data processing capabilities facilitate operation and analysis. The coordinated design of the positioning bracket ensures the accuracy and real-time nature of the measurement, effectively meeting the precise measurement requirements during the assembly and adjustment of aerodynamic and thrust-vector composite rudder systems. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of a synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement, as described in Specific Implementation Method 1.

[0030] Figure 2 This is a schematic diagram illustrating the working principle of a synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement in Specific Implementation Method 1.

[0031] Figure 3 This is a schematic diagram of the cross-section between the rudder surface fixing frame and the rudder surface of the object under test in the second specific implementation method. Detailed Implementation

[0032] Specific Implementation Method 1: Combination Figures 1 to 2This embodiment describes a real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement, which includes a CCD camera 2, a laser sensor group, and a data processing unit 7.

[0033] The laser sensor group includes a coaxial laser sensor 3 and four sets of control surface laser sensors 4; the coaxial laser sensor 3 is used to perform non-contact real-time measurement on the outer surface of the cylinder of the object under test 6 to obtain the first image data of the outer surface of the cylinder; the four sets of control surface laser sensors 4 are used to perform non-contact real-time measurement on the four control surfaces of the object under test 6 to obtain the second image data of the four control surfaces.

[0034] The CCD camera 2 is set at the tail of the object under test 6 and is used to acquire images of the inside of the cylinder of the object under test 6 and obtain third image data of the inside of the cylinder.

[0035] The data processing unit 7 is used to receive first image data, second image data, and third image data, and calculate the coaxiality of the cylinder of the test object 6 based on the first image data. Based on the coaxiality of the cylinder, the actual centerline position and attitude of the cylinder of the test object 6 are obtained. The actual centerline of the cylinder of the test object 6 is used as the reference axis for the rudder deflection angle of the rudder surface and the rudder deflection angle of the cylinder. Based on the second image data and the coaxiality of the cylinder, the rudder deflection angle of the rudder surface of the test object 6 is calculated. Based on the third image data and the coaxiality of the cylinder, the rudder deflection angle of the cylinder of the test object 6 is calculated.

[0036] In this embodiment, the coaxiality of the test object 6 cylinder is calculated based on the first image data. The actual centerline position and attitude of the test object 6 cylinder are obtained based on the coaxiality of the cylinder. The actual centerline of the test object 6 cylinder serves as the reference axis for the rudder deflection angle of the control surfaces and the cylinder's rudder deflection angle. All four rudder deflection angles are defined relative to this actual centerline. If the coaxiality deviation of the cylinder is too large, the subsequently calculated rudder deflection angles will carry systematic errors. The coaxial laser sensor 3 detects the test object 6 cylinder to determine whether the mechanically calibrated test object 6 is coaxial. After coaxiality is achieved, the rudder surface laser sensor 4 measures the control surface data. The control surface laser sensor 4 can provide area array ranging, giving the tangential deflection angle and normal deflection angle of the test object 6; where tangential refers to the radial direction of the test object 6, and normal refers to the axial direction of the tail fin of the test object 6; the normal deflection angle represents the offset angle of the control axis of the test object 6, and the tangential deflection angle represents the deflection angle of the control surface of the test object 6 relative to the control axis; when calibrating the standard test target, the data measured by the standard part can be recorded as the standard value, and the difference between the standard value and the subsequent measurement is used for tooling calibration; the standard value measured by the standard part can be used as the basic standard for dynamic testing, and the measured data is all subtracted from it to obtain the rotation angle in the dynamic process.

[0037] Workflow:

[0038] After power-on, it checks whether the laser sensor group and CCD camera 2 are normal and completes self-test; it triggers the laser sensor group and CCD camera 2 to start working; it allows manual input or import of pre-collected standard target values.

[0039] It offers both static and dynamic modes:

[0040] In static mode, the laser sensor group and CCD camera 2 provide and display the deflection values ​​of each rudder in real time.

[0041] In dynamic mode, the laser sensor group and CCD camera 2 provide and display the deflection values ​​of each rudder in real time, and can manually or automatically store the deflection angle of each rudder. Data can also be saved by external triggering through secondary development.

[0042] Both the coaxial laser sensor 3 and the four sets of control surface laser sensors 4 use structured light + MEMS scanning for detection and imaging. At the same time, the control surface laser sensors 4 can rely on the coaxial sensor 3 for numerical correction. The real-time detection system described in this embodiment achieves synchronous, real-time, and non-contact control surface deflection detection for the first time, avoiding the inefficiency caused by point-by-point measurement. The laser ranging accuracy reaches 0.1mm, eliminating the human error and mechanical wear of contact tools. It can monitor the deflection state of the control surface in real time during assembly or movement, solving the problem that existing detection methods cannot reflect dynamic deformation.

[0043] Specific Implementation Method Two: Combination Figure 3 This embodiment further defines the real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Embodiment 1. In this embodiment, a positioning bracket 1 is also included.

[0044] The positioning bracket 1 includes a base plate 1-1, a first load-bearing plate 1-2, a second load-bearing plate 1-3, and a rudder surface fixing frame 1-4;

[0045] The first load-bearing plate 1-2, the second load-bearing plate 1-3 and the rudder surface fixing frame 1-4 are all arranged sequentially on the base plate 1-1 along the length direction of the base plate 1-1, and the first load-bearing plate 1-2 is located at the head of the object to be tested 6, and the rudder surface fixing frame 1-4 is located at the rudder surface of the object to be tested 6.

[0046] The first load-bearing plate 1-2 is provided with a first hydraulic adjustment mechanism on its side wall, and the second load-bearing plate 1-3 is provided with a second hydraulic adjustment mechanism at its bottom. The central axis of the cylinder of the object to be tested 6 is adjusted by the first hydraulic adjustment mechanism and the second hydraulic adjustment mechanism so that the central axis of the cylinder coincides with the optical axis of the CCD camera 2.

[0047] The coaxial laser sensor 3 and the four sets of rudder surface laser sensors 4 are all fixed inside the rudder surface fixing frame 1-4.

[0048] In this embodiment, the dimensions of the object to be tested 6 are Φ160mm × 3500mm, and the load-bearing capacity of the positioning bracket 1 is not less than 300kg. The positioning bracket 1 has degrees of freedom to achieve overall horizontal adjustment and coaxial calibration of the object to be tested 6. The upper surfaces of the first load-bearing plate 1-2 and the second load-bearing plate 1-3 are provided with grooves, which are used to hold the object to be tested 6. When the first load-bearing plate 1-2 is horizontally misaligned using a hydraulic adjustment mechanism, the coaxiality of the object to be tested 6 can be adjusted to achieve coaxial calibration. When the height of the second load-bearing plate 1-3 is adjusted using a hydraulic adjustment mechanism, the object to be tested 6 can be made to be in a horizontal state. Furthermore, the first load-bearing plate... The height of the lowest point of groove 1-2 plus the radius of the object under test 6 is equal to the height of CCD camera 2; the positioning bracket 1 ensures the rigid alignment of the object under test 6 (aircraft) with the laser sensor group and CCD camera 2, avoiding measurement deviations caused by vibration or human movement, and improving the stability of the system; the hydraulic adjustment mechanism can quickly calibrate the attitude of the cylinder of the object under test 6, reduce the time of manual intervention, and adapt to the assembly and adjustment requirements of different models of the object under test 6; the control surface fixing frame 1-4 is used to fix the coaxial laser sensor 3 and the four sets of control surface laser sensors 4, avoiding external environmental interference (such as airflow, dust) and extending the equipment life.

[0049] Specific Implementation Method 3: This implementation method further defines the real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Implementation Method 2. In this implementation method, the positioning bracket 1 also includes auxiliary plates 1-5.

[0050] The auxiliary plate 1-5 is fixed on the base plate 1-1, and the auxiliary plate 1-5 is located at the tail of the object to be tested 6;

[0051] The CCD camera 2 is mounted on the front of the auxiliary plates 1-5.

[0052] In this embodiment, in order to facilitate adjustment, the CCD camera 2 is positioned at the center of the front of the auxiliary plate 1-5. The auxiliary plate 1-5 ensures that the CCD camera 2 and the central axis of the cylinder of the object under test 6 are strictly coaxial, thereby eliminating geometric distortion in image acquisition and improving the accuracy of image acquisition by the CCD camera 2.

[0053] Specific Implementation Method 4: This implementation method further defines the synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Implementation Method 1. In this implementation method, a display 5 is also included.

[0054] The display signal input terminal of the display 5 is connected to the display signal output terminal of the data processing unit 7; and the display 5 is fixed on the top of the auxiliary plate 1-5.

[0055] In this embodiment, the data output by the data processing unit 7 is transmitted to the host computer, which then transmits it to the display 5 for real-time display. The data can be stored automatically or manually as needed. The data processing unit 7 is ultimately formed into a board and inserted into the industrial control computer in the cabinet for operation.

[0056] In this embodiment, the display 5 is used to display the measurement results in real time, which reflects the optimization of human-computer interaction. That is, the operator can visualize parameters such as rudder deflection angle and coaxiality in real time and quickly discover assembly abnormalities (such as rudder surface zero position deviation). The intuitive interface reduces the dependence on the operator's professional experience and is suitable for complex aerospace assembly scenarios.

[0057] Specific Implementation Method Five: This implementation method further defines the synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Implementation Method Three. In this implementation method, the field of view of the rudder surface laser sensor 4 is greater than 96 mm × 96 mm, and the ranging accuracy of the rudder surface laser sensor 4 is 0.1 mm.

[0058] In this embodiment, the wide field of view coverage is adapted to different sizes of control surfaces (such as large gas turbine control surfaces), avoiding missed detection of edge areas. The 0.1mm accuracy far exceeds that of existing contact tools (such as mechanical protractors with ±1° error), meeting the stringent aerospace standards.

[0059] Specific Implementation Method Six: This implementation method further defines the synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Implementation Method One. In this implementation method, the field of view of the coaxial laser sensor 3 is greater than 96 mm × 96 mm, and the ranging accuracy of the rudder surface laser sensor 4 is 0.1 mm.

[0060] In this embodiment, the large field of view coverage adapts to control surfaces of different sizes (such as large gas turbine control surfaces), avoiding missed detection of edge areas. The 0.1mm accuracy far exceeds that of existing contact tools (such as mechanical protractors with ±1° error), meeting stringent aerospace standards. The unified field of view and accuracy of the coaxial laser sensor 3 and the control surface laser sensor 4 avoid scale differences during data fusion, improving algorithm processing efficiency.

[0061] Specific Implementation Method Seven: This implementation method further defines the synchronous real-time detection system for rudder deflection angle based on laser and CCD image measurement described in Specific Implementation Method One. In this implementation method, the data processing unit adopts an FPGA chip.

[0062] The operating temperature range of the FPGA chip is 5℃~35℃; the storage temperature range of the FPGA chip is -10℃~+40℃; the relative humidity range of the FPGA chip is 20%~80%; the power supply parameters of the FPGA chip are 5V, 10A.

[0063] In this embodiment, the power supply for the laser sensor array is 5V, 2A × 5 channels; the CCD camera has a 2-point power supply of 12V, 5A; and the FPGA has a power supply of 5V, 10A. The overall power supply requirements are: AC voltage: 220V±22V; frequency: 50Hz±2.5Hz. The parallel processing architecture of the FPGA chip can simultaneously analyze data from multiple laser sensors and CCD cameras with latency as low as milliseconds, adapting to high-speed dynamic measurements. It features a wide operating temperature range (5°C~35°C) and humidity resistance (20%~80%), matching the complex environments of aerospace workshops (such as temperature differences and electromagnetic interference); and 220V±10% AC mains power self-adaptation eliminates the need for additional voltage regulators, reducing deployment costs.

[0064] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.

Claims

1. A real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement, characterized in that, Includes a CCD camera (2), a laser sensor group and a data processing unit (7); The laser sensor group includes a coaxial laser sensor (3) and four sets of rudder surface laser sensors (4); the coaxial laser sensor (3) is used to perform non-contact real-time measurement on the outer surface of the cylinder of the object under test (6) to obtain the first image data of the outer surface of the cylinder; the four sets of rudder surface laser sensors (4) are used to perform non-contact real-time measurement on the four rudder surfaces of the object under test (6) to obtain the second image data of the four rudder surfaces. The CCD camera (2) is set at the tail of the object to be tested (6) and is used to collect images of the inside of the cylinder of the object to be tested (6) and obtain third image data of the inside of the cylinder. The data processing unit (7) is used to receive first image data, second image data and third image data, and calculate the coaxiality of the cylinder of the object under test (6) based on the first image data, and obtain the actual central axis position and attitude of the cylinder of the object under test (6) based on the coaxiality of the cylinder, and the actual central axis of the cylinder of the object under test (6) is used as the reference axis for the rudder deflection angle of the rudder surface and the rudder deflection angle of the cylinder; and calculate the rudder deflection angle of the rudder surface of the object under test (6) based on the second image data and the coaxiality of the cylinder. The deflection angle of the test object (6) cylinder is calculated based on the third image data and the coaxiality of the cylinder.

2. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 1, characterized in that, It also includes a positioning bracket (1); The positioning bracket (1) includes a base plate (1-1), a first load-bearing plate (1-2), a second load-bearing plate (1-3), and a rudder surface fixing frame (1-4). The first load-bearing plate (1-2), the second load-bearing plate (1-3), and the rudder surface fixing frame (1-4) are all arranged sequentially on the base plate (1-1) along the length direction of the base plate (1-1), and the first load-bearing plate (1-2) is located at the head of the object to be tested (6), and the rudder surface fixing frame (1-4) is located at the rudder surface of the object to be tested (6). The first load-bearing plate (1-2) is provided with a first hydraulic adjustment mechanism on its side wall, and the second load-bearing plate (1-3) is provided with a second hydraulic adjustment mechanism at its bottom. The central axis of the cylinder of the object to be tested (6) is adjusted by the first hydraulic adjustment mechanism and the second hydraulic adjustment mechanism so that the central axis of the cylinder coincides with the optical axis of the CCD camera (2). The coaxial laser sensor (3) and the four sets of rudder surface laser sensors (4) are all fixed inside the rudder surface fixing frame (1-4).

3. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 2, characterized in that, The positioning bracket (1) also includes auxiliary plates (1-5); The auxiliary plate (1-5) is fixed on the base plate (1-1), and the auxiliary plate (1-5) is located at the tail of the object to be tested (6); The CCD camera (2) is mounted on the front of the auxiliary plate (1-5).

4. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 3, characterized in that, It also includes a display (5); The display signal input terminal of the display (5) is connected to the display signal output terminal of the data processing unit (7); and the display (5) is fixed on the top of the auxiliary plate (1-5).

5. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 1, characterized in that, The field of view of the rudder surface laser sensor (4) is greater than 96 mm × 96 mm, and the ranging accuracy of the rudder surface laser sensor (4) is 0.1 mm.

6. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 1, characterized in that, The field of view of the coaxial laser sensor (3) is greater than 96 mm × 96 mm, and the ranging accuracy of the rudder surface laser sensor (4) is 0.1 mm.

7. The real-time synchronous detection system for rudder deflection angle based on laser and CCD image measurement according to claim 1, characterized in that, The data processing unit uses an FPGA chip; The operating temperature range of the FPGA chip is 5℃~35℃; the storage temperature range of the FPGA chip is -10℃~+40℃; the relative humidity range of the FPGA chip is 20%~80%; the power supply parameters of the FPGA chip are 5V, 10A.

Images