Three-Point Inverse and Forward Kinematic Algorithms for Circle Measurement from Distributed Displacement Sensor...

Area of Science:

• Mechanical Engineering
• Metrology
• Quality Control

Background:

• Accurate arc measurement is crucial for mechanical component manufacturing.
• Current inspection methods are often infeasible or uneconomical for mass production.
• Existing techniques face challenges with measurement complexity, hardware, and algorithmic errors.

Purpose of the Study:

• To introduce a novel validation procedure for measuring arcs using distributed sensors.
• To enhance measurement throughput and reduce errors in automated quality control.
• To develop a robust model for accurate and rapid arc inspection.

Main Methods:

• Development of a three-point inverse kinematic algorithm (TPIK).
• Utilizing a calibration master to solve six non-linear equations for system calibration.
• Validation through mathematical, CAD, and experimental models.
• Introduction of a modified roundness index based on forward and inverse algorithms.

Main Results:

• The TPIK algorithm significantly improves measurement accuracy and throughput.
• The proposed method reduces machine and algorithmic errors in arc measurement.
• Simulations demonstrate the roundness index's sensitivity to measurement precision, sampling angle, and part variation.
• Elimination of human error associated with part loading variations.

Conclusions:

• The developed method offers accurate and rapid inspection of radii for mechanical components.
• This approach is highly suitable for inspecting large quantities of manufactured parts.
• The TPIK algorithm and modified roundness index provide a reliable solution for automated quality control.