In-situ Shape Error Measurement of Large-Scale Torus
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Solution Overview
Problem
Current methods fail to accurately measure shape errors in large-scale annular parts such as aircraft engines and centrifugal compressors, as full indicator movement error is a comprehensive reflection of both position and shape error, and existing instruments like flatness and three-coordinate measuring instruments are not suitable for measuring shape errors of these complex and heavy components.
Innovation Solution
A system comprising an attitude adjusting platform, a rotating index plate, and a measuring part with contact sensors, where the attitude adjusting platform allows for precise adjustment of angles, the rotating index plate enables manual rotation and fixation, and the measuring part uses sensor jacks and contact sensors to transmit data for analysis via Labview, specifically designed for in-situ measurement of large-scale toruses and flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If full indicator movement method is used to measure large-scale annular parts, then the measurement can be performed, but the shape error cannot be accurately obtained as it is mixed with position error
Solution Approach 1:
The measurement process is segmented into multiple stages: first measuring the complete indicator movement to obtain comprehensive data, then separating the shape error component from the position error component through mathematical processing. This segmentation allows accurate extraction of shape error information that would otherwise be lost in the combined measurement.
Solution Approach 2:
A computer control system acts as an intermediary to process the measurement data. The system uses software algorithms to separate shape error from position error in the indicator movement data, enabling accurate shape error measurement without requiring separate measurement procedures.
2Measurement precision
If flatness instrument or three-coordinate measuring instrument is used, then specific morphology can be measured, but these instruments are not applicable to large-scale annular parts with complex structure and heavy weight
Solution Approach 1:
The measurement system uses a dynamic indicator that can rotate and adjust its position to accommodate the large-scale annular parts. The indicator can be manually rotated to different angular positions and manually adjusted to different radial positions, enabling the system to adapt to the complex geometry and large dimensions of the parts being measured.
Solution Approach 2:
The system employs manual adjustment mechanisms that allow the operator to directly position and orient the indicator according to the specific measurement requirements. The manual rotation and positioning capabilities enable the system to self-adapt to various part configurations without requiring complex automated positioning systems.
3Ease of operation
If in-situ measurement is performed on complex and heavy annular parts, then the measurement can be conducted, but the measurement reliability is compromised due to difficulty in maintaining measuring head parallelism
Solution Approach 1:
Before performing the actual shape error measurement, the system first adjusts the indicator to measure the complete indicator movement and establishes the baseline parallelism. This preliminary action allows the system to compensate for any misalignment issues before the main measurement process begins, ensuring reliable results.
Solution Approach 2:
The system uses feedback from the indicator movement measurements to continuously monitor and adjust the measuring head parallelism. By analyzing the measured data in real-time, the system can detect and correct any deviation from the expected parallelism, maintaining measurement reliability throughout the in-situ measurement process.
Data Source
AI summary
Disclosed is a system for shape error in-situ measurement of large-scale torus, which comprises an attitude adjusting part, a rotating part and a measuring part. The attitude adjusting part comprises an attitude adjusting platform, an attitude adjusting platform motor and an adapter panel, wherein the attitude adjusting platform can adjust the rotation angles along z-axis and x-axis, the angle adjusted is controlled by the attitude adjusting platform motor, and the attitude adjusting part is connected with the rotating part through the adapter panel; the rotating part comprises a rotating index plate base and a high-precision rotating index plate which is released from fixation by a lever for rotating, rotated manually for a required angle, and then fixed again by restoring the lever; the measuring part comprises a sensor clamp, sensor holders, contact sensors and associated equipment, wherein the sensor clamp is positioned with the rotating index plate by a mandrel and then fixed by two bolts and nuts; and the sensor clamp has four groups of sensor jacks in total, with at least three jacks in each group, and a sensor holder is installed in each sensor jack and used for fixing each sensor.