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A curved edge diffraction-utilized displacement sensor for spindle metrology.

ChaBum Lee1, Satish M Mahajan2, Rui Zhao1

  • 1Department of Mechanical Engineering, Tennessee Technological University, 1 William L. Jones Dr., Cookeville, Tennessee 38505, USA.

The Review of Scientific Instruments
|August 1, 2016
PubMed
Summary
This summary is machine-generated.

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A novel diffraction-based sensor accurately measures curved surfaces on precision spindles, overcoming limitations of traditional capacitive sensors. This advancement enables convenient, low-cost in situ health monitoring for critical machinery.

Area of Science:

  • Metrology and Instrumentation
  • Precision Engineering
  • Optical Sensing

Background:

  • Traditional non-contact sensors (capacitive, eddy current) for spindle error measurement are designed for flat surfaces.
  • Measuring curved spindle surfaces with existing sensors introduces significant errors due to differing electric field behavior.
  • A need exists for accurate metrological sensing principles applicable to curved surfaces in precision machinery.

Purpose of the Study:

  • To introduce and validate a new dimensional metrological sensing principle for curved surfaces using curved edge diffraction.
  • To address the limitations of current sensors in measuring spindle systems with cylindrical or spherical artifacts.
  • To provide an accurate, convenient, and low-cost method for in situ health monitoring of precision spindles.

Main Methods:

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  • A laser is directed at the cylindrical spindle surface, and a photodetector captures the diffraction field.
  • The proposed optical sensor is compared against a capacitive sensor (CS) over a 500 μm range.
  • Dynamic characteristics (natural frequency, damping ratio) and spindle runout are measured using the new sensor.

Main Results:

  • The novel sensor demonstrated a discrepancy of only 0.017% compared to CS over the full range.
  • Achieved sensing performance includes a resolution of 14 nm and minimal drift (<10 nm over 7 min).
  • Measured spindle dynamic characteristics: natural frequency 181.8 Hz, damping ratio 0.042; spindle runout 22.0 μm at 2000 rpm.

Conclusions:

  • The curved edge diffraction principle offers a viable solution for accurate curved surface metrology.
  • The developed sensor enables precise in situ monitoring of precision spindle systems.
  • This technique promises accurate, convenient, and cost-effective health assessment for critical rotating machinery.