A systematic error modeling and separation method for the special cylindrical profile measurement based on 2-dimension laser displacement sensor

Abstract

The aim of this study is to improve aeroengine multistage rotor performance and to reduce the incidence of failures. Measuring the form error of seam allowance connecting cylindrical surface accurately is critical to achieve rotor optimal stack assembly stage-by-stage. In this paper, compared to the traditional cylindrical profile measurement model, a more comprehensive measurement model was built based on a 2-dimensional line laser sensor measurement technique, a model in which the component eccentricity error e, the sensor lateral offset error d, the sensor forward tilt error θx, the sensor lateral tilt error θy, and the rotary table tilt error γ were gradually modeled and separated. The particle swarm optimization algorithm was adopted to solve the model error parameters. The residual error simulation was performed to observe the effect of different levels of offset errors on the measurement results. The aeroengine rotor seam allowance surface measurement experiment was performed to verify the validity of the method model. We can conclude that the sensor lateral offset error d was 3.214 µm, sensor forward tilt error θx was 12.754″, sensor lateral tilt error θy was 10.365″, and rotary table tilt error γ was 2.146″. The cylindricity error value was 3.701 µm. Compared with the traditional cylindrical profile measurement method, the measurement accuracy of cylindricity error was improved by 1.768 µm. The proposed method can improve the measurement accuracy significantly of multistage rotors in the aeroengine measurement process; besides, it can also be extended to the measurement of other geometric form errors.

Measuring Point Planning and Fitting Optimization of the Flange and Spigot Structures of Aeroengine Rotors

“…Compared with the traditional Limacon model, the accuracy of rotor roundness has been improved by 2.2 µm, and the accuracy of coaxiality has been improved by 9.39 µm [35,36]. Zhang et al constructed a particle swarm optimization algorithm for fitting aeroengine rotor models based on a two-dimension laser displacement sensor, and the measurement accuracy of cylindricity error was improved by 1.768 µm compared with the traditional method [37]. Wang et al used the equivalent homogenization processing and 3D LS method for fitting aeroengine rotor annular plane [38].…”

Decoupling method for four-degree-of-freedom automatic centering and tilting worktable

“…Aero-engine assembly is the last part of the aero-engine manufacturing process, and its assembly quality will directly affect the performance, reliability, and life of the aero-engine [1][2][3][4][5], and the poor assembly may lead to serious vibration or even collision when the rotor rotates at high speed, which is related to the stable operation and safety of the aviation system [6][7][8][9]. The multi-stage rotors in aero-engines are cylindrical components of the rotary symmetry class, and there is a problem of gradual accumulation of machining errors of rotors at all levels during the assembly process [10][11][12], so the precision measurement of single-stage rotor circular contours is a prerequisite and basis for ensuring the rationality of the assembly process. In order to carry out highprecision measurement of the contours of rotary-type parts, it is necessary to ensure that the measured workpiece and the rotary axis are as coaxial as possible [7,[13][14][15], then the workpiece should be adjusted for eccentricity and tilt before each measurement.…”