面向"测量/加工"一体化的强反光复杂金属结构件原位测量方法研究

The integration of measurement and machining based on smart manufacturing is an advanced manufacturing model to ensure the precision machining of complex metal components, the key of which is in-situ measurement techniques. However, due to ambient light in field and complex features of components, the existing optical 3D measurement methods for high-reflective surfaces are difficult to guarantee measurement accuracy, cannot measure the area of multiple reflections and fail to acquire step edge data. Therefore, new theories and methods need to be explored. The situ high-accucay measurement method of dense point clouds for high-reflective complex metal components is to be researched based on heterodyne multi-frequency phase principle in the project. The key techniques to be broken through are: the adaptive optimization method of measurement parameters based on the 3D measurement error modeling, the phase stereo matching method under multi-reflective conditions based on phase aliasing modeling, and the phase distortion modeling and correction principle for the data on step edges. The evaluation criteria for the situ measurement accuracy of complex metal components will be proposed. The project will solve the problem of the effective acquisition of 3D data on the multi-reflective areas and step edges, and will realize the in-situ high-accuracy measurement for complex metal components under ambient light.The results of the project will lay a theoretical foundation for the development of the situ precision measuring instruments of high-reflective complex metal components. It will promote the development of such advanced manufacturing techniques as the integration of measurement and machining, and has an important value for research and application.

基于智能制造的"测量/加工"一体化技术是保证现代复杂金属结构件精密加工的先进制造模式，其关键在于原位测量技术。但由于现场环境光干扰大和结构件特征复杂，现有强反光表面光学三维测量方法存在测量精度难以保证、多次反射区域无法测量和阶跃边缘数据失效等瓶颈问题，亟待探索研究新的理论和方法。 本项目基于外差多频相位技术,研究强反光复杂金属结构件稠密点云原位高精度测量方法，拟突破三维测量误差传递建模与测量参数自适应优化、多次反射条件下的条纹混叠区域建模与相位立体匹配方法、阶跃边缘相位失真建模与校正等关键技术，建立复杂金属结构件原位测量精度评价准则，解决多次反光区域和阶跃边缘处的三维数据有效获取问题，实现环境光干扰下的复杂金属结构件原位高精度测量。本项目成果将为强反光复杂金属结构件精密原位测量仪器研发提供理论基础和技术支持，有助于促进"测量/加工"一体化等先进制造技术的发展，具有重要的研究意义和应用价值。

项目针对现代航空结构件中强反光表面自适应光学三维测量、多次反光干扰下三维测量和阶跃边缘数据失效等瓶颈问题，基于外差多频相位技术,提出了强反光复杂金属结构件稠密点云自适应高精度测量方法、基于选择性投射的多次反射条件下高精度三维测量方法和基于阶跃边缘相位校正的高精度边缘三维测量方法，解决多次反光区域和阶跃边缘处的三维数据有效获取问题，实现环境光干扰下的复杂航空结构件原位高精度测量。本项目成果将为强反光复杂金属结构件精密原位测量仪器研发提供理论基础和技术支持，有助于促进“测量/加工”一体化等先进制造技术的发展，具有重要的研究意义和应用价值。