基于机床伺服轴与传感器复合的大齿轮在机检测方法研究

Various errors of large-scale gears urgently need to be measured with high efficiency and high speed in order to accommodate the entirely scaling-up modern equipments. Aiming at this object, the on-machine measurement system together with the geometrical error models are to be established by this project so as to obtain the influence law arisen from the geometrical errors of the machine tool, the errors of the probe system etc applying on the on-machine measurement accuracy for large-scale gears. Taking the characteristics of the slowly decreasing temperatures of the machine tool and the gears etc in the on-machine measurement process into consideration, the relationships among the component variables and the relationships among the temperature variables and thermal errors will be obtained based on the grey correlation degree. The mapping model between the thermal deformation and the thermal field is to be constructed by adopting the nonlinear mapping functions of the least square multi-class support vector machine. Based on the error transfer principle of multi-body systems, the volumetric error compensation model with power series polynomials is to be implemented and a post compensation method of the synthesized errors is to be introduced in order to separate the errors from measured data and to correct the measured data. Aiming at increasing the on-machine inspection efficiency of large-scale gears, the on-machine measurement software system is to be integrated effectively into the CNC system of the machine tool by embedding the on-machine software into the CNC system of the machine tool for large-scale gears. Taking the gear with the size of four meters used for the transmission system of ships as an example, experimental studies of the on-machine measurements are to be processed on the CNC gear form-grinding machine tool to verify the measurement methods and the error compensation theories etc.

现代装备的整体大型化迫切需要对大齿轮各项误差进行高效快速准确的检测。为此本项目构建大齿轮在机检测系统，并建立几何误差模型，获得大齿轮在机测量系统中加工用机床几何误差、测头系统误差等对大齿轮在机检测精度的影响规律。针对在机测量过程中，机床及齿轮等温度缓变下降的特点，基于灰色关联度建立在机测量系统中零部件温度变量之间以及温度变量与热误差之间的对应关系，采用最小二乘多分类支持向量机的非线性映射功能建立热变形与温度场映射模型。基于多体系统误差传递原理，研究幂级数多项式空间误差综合补偿模型，提出一种误差综合后补偿方法，从测量数据中分离出误差修正测量数据。将大齿轮在机检测软件嵌入到机床数控系统，实现大齿轮在机测量软件系统与机床数控系统的有效集成，以达到大齿轮在机快速测量的目的。以舰船变速箱用的4米大齿轮为例，在数控成形砂轮磨齿机进行在机测量的实验研究，对测量方法及误差补偿等理论进行验证。

现代装备的整体大型化迫切需要对大齿轮各项误差进行高效快速准确的检测。为此本项目构建大齿轮在机检测系统，主要研究了基于加工机床伺服轴的检测系统运动功能配置、齿轮机床几何误差的识别与模型建立、在机测量热误差分析与后补偿机制的研究、在机测量软件系统与机床数控系统的集成等内容。.研究了基于加工机床伺服轴的检测系统运动功能配置方法，构建了基于加工机床伺服轴与传感器复合的、适用于大齿轮的、快速准确的在机测量系统；.提出了采用激光干涉仪辨识了齿轮加工机床的几何误差，建立了齿轮加工机床的综合空间几何误差模型，揭示了在机测量系统中各项几何误差对测量精度的影响机理；.分析了在机测量过程的热误差，建立了大齿轮在机测量的热变形与温度场的数学映射模型，以及幂级数多项式空间误差后补偿模型，提出了适用的后补偿的误差综合补偿机制；.开发了在机测量软件，并实现了与齿轮加工机床数控系统的集成，完成直径2米-4米大齿轮在机测量实验研究、系统软件开发及与机床数控系统的集成，分别应用在了高、中、低三种精度等级的齿轮在机测量中，进行了齿轮精度在机测量考核实验，结果表明，其测量精度达到机床能够加工齿轮的精度等级所规定公差带的三分之一之内，有效提高了齿轮在机测量的精度。.该项目研究成果应用于企业的大规格数控成形砂轮磨齿机，填补了国内空白，为我国开发系列高档、大规格、精密数控磨齿机、实现齿轮磨床全面替代进口奠定了坚实的基础。.本项目针对研究领域的国内外研究前沿，结合企业新产品开发和新技术发展需要，在成形砂轮磨齿机在机测量理论和实际应用方面作了大量的研究工作，圆满地完成了预期的研究计划，研究成果具有重要的理论和实际应用价值。