Abstract
In this study, three-probe error separation was developed with three chromatic confocal displacement sensors for roundness measurement. Here, the harmonic suppression is discussed first to set suitable orientation angles among three sensors. Monte Carlo simulation is utilized to test the error separation and optimize the orientation angles and off-axial distance. The experimental setup is established using chromatic confocal sensors with a precise rotary platform. The experimental results show that the measured roundness with an orientation-angle combination of (0°, 90.1°, and 178.6°) is much better than that of another nonoptimal selection (0°, 90.4°, and 177.4°). The roundness error is only 0.7% between the proposed measurement system and an expensive ultraprecision roundness meter. Furthermore, it is proven that the eccentricity distance should be decreased as small as possible to improve the measurement accuracy. In sum, this paper proposes a feasible method for roundness measurement with reliable simulations, easily integrated sensors, and an ordinary precision rotary platform.
Highlights
Roundness is one of the most important geometrical specifications of rotational workpieces for product-quality estimation, in situ processing optimization, and spindle accuracy test [1, 2]
To obtain a suitable orientation-angle combination with big intervals, the Monte Carlo simulation was performed to explore the influence of orientation angles on the error separation accuracy of the cylindrical workpiece
The results show that when the orientation angle β changes within 2° away from 180°, the roundness error varies little with a different orientation angle α
Summary
Roundness is one of the most important geometrical specifications of rotational workpieces for product-quality estimation, in situ processing optimization, and spindle accuracy test [1, 2]. Except for the accuracy of the probe, the rotation error of the rotary platform should be as small as possible to ensure that all measured displacements begin from the rotation axis In this way, the profile of the workpiece is reconstructed with radial displacement. The high-precision rotary platform is usually expensive, and the eccentricity error of the displacement sensor seriously affects the measurement accuracy. The valid spot sizes on the workpiece surface of capacitance sensors or triangulation laser sensors are always as big as a millimeter lever This condition will seriously affect the lateral resolution in the profile reconstruction, which may cause a certain roundness measurement error, especially for workpieces with a small radius. We explored the actual influences of the orientation-angle combination and off-axial distance on the roundness measurement
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