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A Combined Sensor Design Applied to Large-Scale Measurement Systems.

Xiao Pan1, Huashuai Ren1, Fei Liu1

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Summary

This study introduces a novel multi-node fusion sensor for accurate large-space measurements. The combined sensor effectively measures hidden points and free-form surfaces on large components, improving industrial inspection capabilities.

Keywords:
combined sensorlarge-space measurement systemmulti-node fusionprecision measurementsignal conditioning

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Area of Science:

  • Metrology and Measurement Science
  • Optical Sensing Technologies
  • Mechanical Engineering and Design

Background:

  • Photoelectric sensing units are critical for large-space measurement accuracy.
  • Existing systems struggle with precise measurement of hidden points and free-form surfaces in large components.

Purpose of the Study:

  • To design and validate a multi-node fusion combined sensor for enhanced large-space measurement accuracy.
  • To address limitations in measuring complex geometries and occluded areas within large structures.

Main Methods:

  • Developed a multi-node fusion hidden-point measurement and solution model.
  • Designed an adaptive front-end photoelectric conditioning circuit with signal amplification and filtering.
  • Implemented a nonlinear least-squares calibration method using multi-position vector cone constraints.

Main Results:

  • Achieved a measurement accuracy better than 0.24 mm and standard deviation better than 0.026 mm in a 7000 mm × 7000 mm × 3000 mm area.
  • Demonstrated length measurement accuracy within 0.28 mm.
  • Verified hidden point and free-form surface measurement accuracy below 0.26 mm for components like aircraft hoods.

Conclusions:

  • The developed multi-node fusion sensor significantly enhances large-space measurement capabilities, particularly for challenging geometries.
  • The system meets industrial measurement needs and expands the application scope of large-space measurement technologies.
  • Validated accuracy and precision confirm the sensor's suitability for industrial metrology and quality control.