Aiming at the requirement of high precision real-time measurement of attitude angle in modern manufacturing industry, an attitude measurement system based on a Laser Tracker is constructed. A method of attitude measurement based on 2DPSD and monocular vision is proposed, and a target structure for realizing this method is proposed. Firstly, the rolling angle of the target relative to the camera is calculated by monocular vision, and the laser beam vector is obtained by Laser Tracker and 2DPSD. Then, the relative attitude between the Laser Tracker coordinate system and the camera coordinate system is calculated based on SVD. Finally, the transformation relations of unit vector of laser beam in different coordinate systems are established to calculate the attitude of target relative to Laser Tracker. Experiments show that the method can effectively measure the target attitude information, and the maximum error of attitude angle measurement can be less than 2° within the effective angle range of [- 25°, 25°] and distance range of 3m.
Visible light and infrared light, included in a femtosecond laser tracker, have been widely employed for precise orientation and high-precision ranging measurements of targets, respectively. In the above measurement process, it is always necessary to ensure the coaxiality of those two laser beams with different wavelengths. According to the structural characteristics of the instruments, a calibration method for the coaxiality of tracking light and femtosecond ranging light of the femtosecond laser tracker based on frequency doubling crystal is proposed, which is the detection of the coaxiality deviation caused by the included angle between the beams. We investigate the principle of two-beam laser coaxiality detection and calculate the parameters of the system. The detection system is further developed, and the error analysis is carried out. The results demonstrate that the tracking laser and femtosecond laser is coaxial within an accuracy of 1.5 arc sec, satisfying the measurement requirements.
In the case of industrial field measurement, the present measuring instruments work with manual operation and collimation, which give rise to low efficiency for field measurement. In order to solve the problem, a new type industrial total station is presented in this paper. The new instrument can identify and trace cooperative target automatically, in the mean time, coordinate of the target is measured in real time. For realizing the system, key technology including high precision absolutely distance measurement, small high accuracy angle measurement, target automatic collimation with vision, and quick precise controlling should be worked out. After customized system assemblage and adjustment, the new type industrial total station will be established. As the experiments demonstrated, the coordinate accuracy of the instrument is under 15ppm in the distance of 60m, which proved that the measuring system is feasible. The result showed that the total station can satisfy most industrial field measurement requirements.
The effective application of high performance measurement technology can greatly improve the large-scale equipment manufacturing ability. Therefore, the geometric parameters measurement, such as size, attitude and position, requires the measurement system with high precision, multi-function, portability and other characteristics. However, the existing measuring instruments, such as laser tracker, total station, photogrammetry system, mostly has single function, station moving and other shortcomings. Laser tracker needs to work with cooperative target, but it can hardly meet the requirement of measurement in extreme environment. Total station is mainly used for outdoor surveying and mapping, it is hard to achieve the demand of accuracy in industrial measurement. Photogrammetry system can achieve a wide range of multi-point measurement, but the measuring range is limited and need to repeatedly move station. The paper presents a non-contact opto-electronic measuring instrument, not only it can work by scanning the measurement path but also measuring the cooperative target by tracking measurement. The system is based on some key technologies, such as absolute distance measurement, two-dimensional angle measurement, automatically target recognition and accurate aiming, precision control, assembly of complex mechanical system and multi-functional 3D visualization software. Among them, the absolute distance measurement module ensures measurement with high accuracy, and the twodimensional angle measuring module provides precision angle measurement. The system is suitable for the case of noncontact measurement of large-scale equipment, it can ensure the quality and performance of large-scale equipment throughout the process of manufacturing and improve the manufacturing ability of large-scale and high-end equipment.
In a rotating angle measuring system, errors of grating sensor, installation and rotor run-outs will affect angle measuring error. The error caused by rotor run-outs is usually the biggest and the hardest to eliminate of them. To improve the accuracy, the table should be fabricated precisely, thus, the table system will be complicated and expensive. This paper provides a method to solve the challenge by using two gratings in the same table, whose gratings respectively grooved on end face and side face. The error mechanism of end face and side face caused by axial and radial rotor run-outs by were deduced. It can be concluded from the analysis that end face grating is sensitive when radial rotor run-outs happens, side face grating is sensitive when axial rotor run-outs happens. Due to the conclusion, combined type gratings with one end face grating and one side face grating can be used to restrain the error caused by Rotor Run-outs of table.
A new type femtosecond laser tracker is one high precision measurement instrument with urgent need in science research region and industrial manufacture field. This paper focuses on the operational principle and the structure development of the femtosecond laser tracer, and the method of error compensation as well. The system modules were studied and constructed. The femtosecond frequency comb module was firstly analyzed and developed. The femtosecond laser frequency comb performed perfectly high precise distance measurement for laser tracker. The experimental result showed that the stability of repetition rate reached 3.0×10-12@1s and the stability of carrier envelop offset reached 1.0×10-10@1s. The initial experiment showed that measurement error was less than 1ppm. Later the error compensation module was introduced, and the optoelectronic aiming and tracking control module was built. The actual test result showed that the stability of miss distance was better than 2.0 μm, the tracking speed could reach 2m/s.
Geometric errors in laser trackers such as light offset and transit tilt have essential influence on the system measurement errors. Thus error detection and calibration are very important for producers and customers to execute error compensation. Different methods are developed to detect and calibrate errors. However, the commonly used methods such as length measurement and two-face measurement are sensitive to several misalignments which cannot calibrate errors directly and separately. In this paper a series of methods for detecting and calibrating geometric errors such as mirror tilt, beam tilt and transit tilt were presented which can calibrate geometric errors individually and precisely. The mirror tilt could be detected with the help of two autocollimators and one polygon. Then the beam tilt and offset errors were calibrated using a CCD camera and condenser lenses. Finally the transit tilt error was calibrated using a gradient and a vertical plane. Experiments and error assessment were executed to show that the accuracy of the calibration methods can meet the user’s demand.
There are two light sources in Femtosecond laser tracker, the center wavelengths of which are different. In order to achieve precise distance, light beams from the two sources should be combined. In this paper, key technology of light path alignment for femtosecond laser tracker based on double optical wedge is presented. Precise steering of incident light beam can be realized by changing the angle of the double optical wedge. Method for adjusting the angle and translation of light beam using two pairs of double optical wedge is proposed. Also mathematical model on the basis of vector superposition method is established to correct offset of light beam, which is validated with Zemax.
The working principle and system design of the laser tracker measurement system are introduced, as well as the key technologies and solutions in the implementation of the system. The design and implementation of the hardware and configuration of the software are mainly researched. The components of the hardware include distance measuring unit, angle measuring unit, tracking and servo control unit and electronic control unit. The distance measuring devices include the relative distance measuring device (IFM) and the absolute distance measuring device (ADM). The main component of the angle measuring device, the precision rotating stage, is mainly comprised of the precision axis and the encoders which are both set in the tracking head. The data processing unit, tracking and control unit and power supply unit are all set in the control box. The software module is comprised of the communication module, calibration and error compensation module, data analysis module, database management module, 3D display module and the man-machine interface module. The prototype of the laser tracker system has been accomplished and experiments have been carried out to verify the proposed strategies of the hardware and software modules. The experiments showed that the IFM distance measuring error is within 0.15mm, the ADM distance measuring error is within 3.5mm and the angle measuring error is within 3〞which demonstrates that the preliminary prototype can realize fundamental measurement tasks.
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