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Error Analysis of Normal Surface Measurements Based on Multiple Laser Displacement Sensors
Fantong Meng1, Guolin Yang1, Jiankun Yang2
1State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian 116024, China.
Accurate robotic drilling in aerospace manufacturing requires precise workpiece surface normal measurement. This study introduces a parametric method and simulation to optimize sensor layout, significantly reducing measurement errors for improved drilling accuracy.
Area of Science:
- Aerospace Manufacturing
- Robotics
- Metrology
Background:
- Robotic drilling for assembly holes in aerospace demands precise workpiece surface normal measurement.
- Existing multi-sensor systems lack detailed analysis for optimal layout design and accuracy.
Purpose of the Study:
- To propose a simplified parametric method for designing multi-sensor normal measurement devices with symmetrical layouts.
- To analyze the impact of sensor number, laser beam slant angle, and spot distribution radius on measurement accuracy.
Main Methods:
- Development of a parametric method for device design.
- Simulation of normal measurement error distribution considering random sensor errors.
- Experimental verification on a five-axis precision machine tool.
Main Results:
- Normal measurement error distribution follows a pyramid-like region based on key parameters.
- Increasing laser beam slant angle and spot distribution radius significantly reduces normal measurement errors.
- Optimal parameters (slant angle ≥15°, radius ≥19 mm) achieve <0.05° error.
Conclusions:
- The proposed parametric method and simulation effectively analyze and optimize normal measurement devices.
- Sensor accuracy, quantity, and installation position are critical factors influencing measurement accuracy.
- Achieving high normal accuracy is feasible for robotic drilling applications with optimized sensor configurations.
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