On-line Measurement Method Research Articles

Online Optical Axis Parallelism Measurement Method for Continuous Zoom Camera Based on High-Precision Spot Center Positioning Algorithm

Ensuring precise alignment of the optical axis is critical for achieving high-quality imaging in continuous zoom cameras. However, existing methods for measuring optical axis parallelism often lack accuracy and fail to assess parallelism across the entire focal range. This study introduces an online measurement method designed to address these limitations by incorporating two enhancements. First, image processing methodologies enable sub-pixel-level extraction of the spot center, achieved through improved morphological processing and the incorporation of an edge tracing algorithm. Second, measurement software developed using Qt Creator can output real-time data on optical axis parallelism across the full focal range post-measurement. This software features a multi-threaded architecture that facilitates the concurrent execution of image acquisition, data processing, and serial communication. Experimental results derived from simulations and real data indicate that the maximum average error in extracting the center of the spot is 0.13 pixels. The proposed system provides critical data for optical axis calibration during camera adjustment and inspection.

Online measurement of wear depth based on displacement signal of vertical tester

This paper proposes an accurate and applicable online measurement method of wear depth using displacement signal for vertical testers under mixed lubrication. Firstly, displacement signal is revealed to be composed of temperature drift and Brownian motion. Secondly, the first order Taylor expansion of the Brownian motion is revealed to be the unified form of wear models. Further, the online measurement method is established by introducing non-integer order and amplitude coefficient to eliminate systematic randomness. Finally, the method is verified by graphite-metal tribo-pairs on a standard tester and a high speed friction and wear testing bench, relative errors between online and offline measurement results are less than 10 %, extension errors by non-integer order within its application range are less than 2 %.

Online Measurement of Melt-Pool Width in Direct Laser Deposition Process Based on Binocular Vision and Perspective Transformation.

Direct laser deposition (DLD) requires high-energy input and causes poor stability and portability. To improve the deposited layer quality, conducting online measurements and feedback control of the dimensions, temperature, and other melt-pool parameters during deposition is essential. Currently, melt-pool dimension measurement is mainly based on machine vision methods, which can mostly detect only the deposition direction of a single melt pool, limiting their measurement range and applicability. We propose a binocular-vision-based online measurement method to detect the melt-pool width during DLD. The method uses a perspective transformation algorithm to align multicamera measurements into a single-coordinate system and a fuzzy entropy threshold segmentation algorithm to extract the melt-pool true contour. This effectively captures melt-pool width information in various deposition directions. A DLD measurement system was constructed, establishing an online model that maps the melt-pool width to the offline deposited layer width, validating the accuracy of the binocular vision system in measuring melt-pool width at different deposition angles. The method achieved high accuracy for melt-pool measurements within certain deposition angle ranges. Within the 30°-60° measurement range, the average error is 0.056 mm, with <3% error. The proposed method enhances the detectable range of melt-pool widths, improving cladding layers and parts.

Online soft measurement method for chemical oxygen demand based on CNN-BiLSTM-Attention algorithm

Online soft measurement method for chemical oxygen demand based on CNN-BiLSTM-Attention algorithm

Research and design of a small self-heating high-temperature lithium plugging meter system

In the research of new reactors, lithium has become a research direction as a new coolant after sodium. Lithium working fluids introduce various metallic and non-metallic impurities such as oxygen, calcium, carbon, nitrogen, etc. to a greater or lesser extent during production, filling, and even operation. In addition, the processing, welding, and cleaning steps of the pipeline and equipment in the circuit during manufacturing inevitably result in residual dirt, grease, surface oxides, and moisture. These will have a certain impact on the performance of heat transfer and circuit safety through accelerated corrosion or plugging. Therefore, in high-temperature lithium circuits, the impurity concentration of lithium working fluid must be strictly controlled and purified before use. At present, the detection methods for impurity content in lithium working fluids can be divided into two categories: sampling analysis method and online measurement method. Sampling analysis is the most direct detection and analysis method, which can directly obtain the content of various impurities in lithium working fluids, and the results are relatively accurate; The online detection method can generally only detect non-metallic impurities, but it is relatively fast and simple, and is currently a commonly used measurement method on lithium working fluid devices. The plugging meter method has been studied and used as a rather convenient online detection method. This article introduces a small, self-heating, and mobile high-temperature lithium plugging meter system to meet the online detection of different points in the lithium circuit of system engineering.

Online Measurement Method and System of Excitation Impedance of Current Transformers Based on Norton's Theorem and Differential Method to Measure Difference of Two Currents.

An online measurement method is proposed in this paper, and a system is established for detecting the excitation impedance of current transformers (CTs) based on Norton's theorem. The theorem is carried out by connecting a resistance and an inductance at the secondary side port of the CT to get the equations for calculating the impedance. The iterative method is used to solve the equations, and the solution is revised to consider the nonlinearity of the core. The main variable in the equations is the variation of the secondary current with the resistance or inductance. To obtain the secondary current variation accurately, which is less than 1‱ of the current, a differential method is proposed, which is based on charging two capacitors and measuring the difference of their voltages instead of measuring each current separately first and then obtaining the current variation by subtraction. This is equivalent to saving two currents first and then measuring the current difference. The differential method avoids the problem of error amplification in the process of measuring two currents separately first and then subtracting them to obtain the current variation and solves the problem that two currents do not appear simultaneously. The results verify the correctness and accuracy of the proposed method and system. The acquisition of the excitation impedance is the basis for obtaining the working characteristics of CT cores, including magnetic and loss characteristics, as well as the error of CTs.

Nondestructive measurement of terahertz optical thin films by machine learning based on physical consistency

Optical scattering measurement is one of the most commonly used methods for non-contact online measurement of film properties in industrial film manufacturing. Terahertz photons have low energy and are non-ionizing when measuring objects, so combining these two methods can enable online nondestructive testing of thin films. In the visible light band, some materials are transparent, and their thickness and material properties cannot be measured. Therefore, a method based on physical consistency modeling and machine learning is proposed in this paper, which realizes the method of obtaining high-precision thin film parameters through single-frequency terahertz wave measurement, and shows good performance. Through the experimental measurement of organic material thin films, it is proved that the proposed method is an effective terahertz online detection technology with high precision and high throughput.

Scattered and transmitted light as surrogates for activated carbon residual in advanced wastewater treatment processes: Investigating the influence of particle size

The use of powdered activated carbon (PAC) is a common process in advanced wastewater treatment to remove micropollutants. Retention and separation of PAC is essential as PAC loaded with micropollutants should not be released into the environment. Determining the activated carbon (AC) residual in the effluent poses a challenge, as there is currently no on-line measurement method. In this study, the correlation between turbidity, measured by scattered light, and absorption at wavelength of 550 nm (Absorption550 nm), measured by transmitted light, was investigated in relation to the AC residue. Linear correlations for turbidity (R2 = 0.95) and Absorption550 nm (R2 = 1.00) to AC concentrations were observed in both laboratory and full-scale experiments in a pilot plant where superfine PAC was added prior to Pile Cloth Media Filtration (PCMF). Decreasing the particle size (d50) while maintaining the same AC concentration leads to increased turbidity: Therefore, a fourfold reduction in d50 results in a 2- to 3-fold increase in turbidity, whereas a 30-fold reduction in d50 leads to a 6-to 8-fold increase. Furthermore, the original wastewater turbidity led to a parallel shift in the linear correlation between turbidity and AC. Coagulant doses of up to 400 mg Me3+/g AC resulted in a 50% reduction in turbidity. However, higher concentrations from 400 to 1,000 mg Me3+/g AC resulted in increased turbidity with only a 30% reduction compared to the initial turbidity. The study also highlights the significance of AC particle size in optical measurements, impacting result accuracy.

Research on Online Measurement Method for Small Workpiece Circular Holes Based on Machine Vision

&lt;p&gt;In modern manufacturing, due to the narrow format, short size, and complex surface structure of small-sized workpieces, automatic detection of surface defects, dimensions, etc. on small-sized workpieces faces difficulties, making it difficult to meet the requirements of fully automated production lines. Especially, there is no good solution to the problem of high-precision automatic measurement of geometric features of circles and arcs on small-sized workpieces. This article takes the engine end cover circular hole thermal component as the research object, builds a hardware platform for image acquisition of small-sized workpieces based on machine vision, proposes an online size measurement method for small-sized circular holes, and realizes the measurement of the position size and aperture size of small-sized product shell workpieces. In order to achieve the above methods, this article builds a visual detection hardware system and describes a detailed machine vision hardware selection scheme. Then, the images collected by the system are preprocessed, including image denoising, image correction, and image feature extraction. Then, for the processed images, an improved Hough transform fitting method is used to obtain the online size of features. In order to visualize the results, the detection system and software are designed according to the actual application scenario. The overall scheme of this article is efficient and reasonable, and the detection result error is within a reasonable range.&lt;/p&gt; &lt;p&gt;&amp;nbsp;&lt;/p&gt;

A dynamic method for online measurement and calibrating with Lorentz force velocimetry

Our previous study (Zheng et al 2020 Metall. Mater. Trans. B 51 558–69; Zheng et al 2020 Acta Metall. Sin. 56 929–36) reports a non-invasive in-situ measurement technology using Lorentz force velocimetry (LFV) to quantitatively measure the meniscus velocity of molten steel online. However, effective signal recognition from complex environment noise and determination of zero-point calibration in harsh metallurgical processing is an essentially challenging task and indeed needs further exploration. In this paper, a method of combining double probe arrangement with real-time differential processing technology was proposed, the twin design structure not only enables the measurement of ∼mN Lorentz forces, but also has significant characteristics of environmental tolerance. The Lorentz force signal caused by conductor motion can be accurately calculated through a differential method, meaning that the problem of zero compensation in industrial online measurement can be effectively overcome. Moreover, based on the functional correlation between the Lorentz force and the parameter of the conductor to be measured, a method of the probes moving variably and actively and their data difference ratio processing was adopted, so as to achieve dynamic calibration during online measurement. This measurement strategy provides a new approach for LFV to achieve online dynamic measurement and online calibration, and provides technical support for electromagnetic measurement technology towards engineering applications.

Research on online measurement method of image target size based on binocular vision

Research on online measurement method of image target size based on binocular vision

A new tribo-dynamics modeling and online measurement method for crosshead bearings in marine engines

Due to harsh working conditions, the crosshead bearing is reported to be the bearing with the highest failure rate in marine engines. The dynamics behavior, fluid lubrication, and solid contact are coupled with each other, resulting in great difficulty in predicting the bearing performance. In the current study, a new tribo-dynamics model was proposed by coupling the multi-body dynamics model of the engine with the mixed lubrication model of the crosshead bearing, and the bearing load was monitored in real time for the first time through wireless techniques. The research results indicate that the bearing load predicted by the tribo-dynamics model is in good agreement with the experimental results. Based on the verified model, the impact of various design parameters on the bearing performance was further discussed. Regarding the engine researched in the current study, when the width of the oil groove was selected to be 100 mm and the oil supply pressure was set to be 10 bar, the friction loss of the crosshead bearing is at a low level. In addition, to avoid serious wear, the fit clearance of the crosshead bearing should not exceed 400 μm. These designs have been successfully applied to a certain marine engine.

On-line posture measurement for automatic positioning of foldable-wing with priority-based multi-constraints

The digital assembly system is widely used in the automatic positioning of large aircraft components. Accurate posture measurement of the components remains challenging for high-precision assembly of the components with various engineering constraints. Existing methods often require repeated measurements of key features and are susceptible to the pronounced coupled effect, where various constraints mutually influence the solution of pose parameters. To enhance the efficiency and precision of posture measurement, this study proposes an on-line measurement method for the Foldable-wing Digital Assembly System. The key features and several reference points are measured once by the laser tracker. According to the assembly task sequence, a novel posture evaluation model with priority-based multi-constraints is established to calibrate these reference points which will be utilized as the new datum of posture measurement instead of the traditional key features. This model separately satisfies the various engineering constraints, such as coaxiality, gap, and basic positioning accuracy, in order of priority to avoid the coupling effect between different types of constraints. Consequently, features with higher priority can achieve higher accuracy without weight setting. Next, the reference points are automatically measured to calculate the posture parameters. Considering the uncertainty characteristics of the measuring instrument, the registration algorithm based on weighted total least squares adjustment is applied to reduce measurement uncertainty. Monte Carlo simulation results demonstrate the proposed method's ability to enhance positioning accuracy and reduce posture uncertainty, outperforming conventional methods. Finally, the practical application was successfully implemented, and all key features remained within tolerance.

On-Line Measurement Method for Rheology of Straight Tubular Oil-Based Drilling Fluid Under Pulsating Flow

On-Line Measurement Method for Rheology of Straight Tubular Oil-Based Drilling Fluid Under Pulsating Flow

Online measurement method for dimensions of disk parts based on machine vision.

Online measurement of disk part dimensions by the standard industrial camera features low cost, high efficiency and good universality, but the impact of projection distortion and end face chamfer on measurement is needed to overcome. Present work presents a measurement method to resolve above issues based on machine vision. To improve the measurement accuracy, lower end face of a disk part is determined as calibration plane and the upper end face is measurement plane. To reduce the impact of projection distortion and chamfer on measurement, the measurement points are reconstructed on the measurement plane by re-projection. Then, the inner and outer diameters of disk parts are measured by circle geometric fitting, and the thickness is calculated by the measurement plane position. The experimental results show that the method can online measure disk part dimensions just by a single image, and accuracy meets the requirements of universal grade disk parts.

A Kalman-filtering-based BRDF online measurement method for variable temperature surfaces

Bidirectional Reflectance Distribution Function (BRDF) at variable temperature is important in many applications such as thermal imaging and target detection. However, ensuring long-term stable high temperature control is complex and energy consuming, making online measurements essential. Existing BRDF systems are mainly designed for room temperature measurements, and the widely used quadrature demodulator requires a large amount of stored measurement data and complicate post-processing calculations. In this paper, the Kalman-based demodulator was modified by adding a forgetting factor to improve the demodulation speed and flexibility. This demodulator was implemented on FPGA in both numerical simulations and experiments. The detection of BRDF was demodulated online, reducing measurement time and resource consumption by half compared to the quadrature demodulator. The proposed demodulator can be utilized for further analysis of high-temperature BRDF characteristics of material surfaces.

Single sensor three point on-line measurement method of precision rolling bearings

With the continuous development of machining methods, it is necessary to explore grinding and measuring methods to ensure the fatigue life and improved accuracy of bearings. In this study, a single-sensor three-point (SSTP) on-line outer-diameter measuring instrument was designed to ensure the consistency of the machining accuracy of precision bearing rings. Moreover, the mathematical model of the measuring instrument was established. The roundness and cylindricity error measurements of the ring outer diameter of precision bearings A and B form different manufacturers of countries were compared and analyzed. In addition, the accuracy measurement of the experimental grinder was investigated through multidimensional experiments. The results demonstrated a measuring and repetitive accuracy of ±1.25 and 1 μm, respectively. The measuring results conformed to the 3 б principle. The measured outer diameter was within the actual value of the workpiece outer diameter ±3 б, and the accuracy was over 99.73%. The instrument did only measure the outer diameter, but also measured the waviness error. The outer diameter and rotating speed did not clearly affect the measuring accuracy. The use of a lubricating fluid reduced the contact resistance of the on-line measuring instrument and significantly reduced the absolute error of outer diameter measurement, which is beneficial in improving the outer diameter measurement accuracy of the instrument.

Evaluation Method for Reverse Recovery Characteristics of Thyristors Based on Charge Measurement

The change of operation mode of the HVDC project causes a change of the external characteristic of the converter valve, and the reverse recovery characteristic of the thyristor inside the converter valve changes accordingly. Therefore, the reverse recovery charge measurement values of thyristors under different operating conditions cannot be directly compared, and the status of thyristors cannot be evaluated online. Therefore, a method of measuring the reverse recovery charge of series thyristor based on the turn-off voltage is presented in this paper. Then, the operation mode of the HVDC project is analyzed, and the external characteristics of the converter valve under different operation modes are discussed. Secondly, the external factors that affect the reverse recovery characteristics of thyristors are analyzed essentially, and the relationship between the external factors and the external characteristics of the converter valve is discussed. A reverse recovery charge model considering external factors is established, and a method to reduce the error is proposed. Finally, the reverse-recovery charge normalization coefficient is derived for the normalization of the measured values in different working conditions. Based on the charge online measurement method and the normalization method proposed in this paper, the reverse-recovery characteristic evaluation method of the thyristor is proposed, and the evaluation steps are introduced.

An On-Line Measurement Method of the Medium Thickness Steel Plate Based on Structured Light Vision Sensor

An On-Line Measurement Method of the Medium Thickness Steel Plate Based on Structured Light Vision Sensor

Double Optical Fiber Temperature Compensation Method for Measurement of Interface Pressure Between Simulated Cable and Accessory at High Temperatures

Reliable interface pressure between cables and accessories is closely associated with the safe operation of a power cable system. Using an external optical fiber Bragg grating temperature-compensating curvature sensor, a new method for online measurement of the interface pressure between a cable and an accessory at high temperatures is proposed. On the basis of the sensing principle of a fiber Bragg grating, a mathematical pure bending model, and a model of a thick-walled cylinder, a fiber Bragg grating temperature-compensating curvature sensor is fabricated using Dow Corning Sylgard-184 silicone rubber. The interface pressures of 10 kV cable accessories with different expansion rates at different temperatures are measured. The results of the measurements show that the temperature-compensated deviation of wavelength measurements made by the fiber grating curvature sensor ranges from -2.59% to 5.50%. The interface pressure between the cable and the accessory gradually increases with an increase in temperature from 30 to 60 °C. The results are consistent with the results of measurements made using a traditional piezoelectric sensor. This method is expected to evaluate the long-term reliability of the interface pressure of cable accessories in actual complex-temperature environments.