臺灣博碩士論文加值系統

本論文主要運用TS740觸發式探頭（touch trigger probe）及LK-G80雷射位移計(reflective distant sensors)整合於海德漢控制器五軸CNC加工機上進行加工間檢測（in-process measurement），並針對機上量測幾何誤差與位置誤差進行探討與研究。探頭與雷射位移計經校正後，可用於量測工程特徵與自由曲面，極適合應用在五軸CNC加工機上進行綜合性量測。
在量測系統架構上，將觸發式探頭及雷射位移計在五軸CNC加工機上進行軟硬體整合。量測點資料分析程式使用MATLAB軟體撰寫，可進行加工間檢測點座標運算，得出幾何形狀誤差或位置誤差。本研究使用ISO切削測試標準件與自行設計四凸一凹自由曲面整合之載具做為量測標的，非接觸式量測時由刀軸投影置待測物量測；接觸式量測則沿量測面之法向量量測，分別規劃量測路徑後進行量測。
在進行量測結果誤差比對方面時，本研究利用CNC三次元座標量測儀（CMM）量測相同工件，與加工間檢測數值進行誤差比對分析，五軸CNC機上量測結果相對於CMM量測之誤差，對自由曲面之最大誤差為0.0485 mm，而對規則形狀量測幾何公差的最大誤差分別為：真直度0.00406 mm、真平度0.00068 mm、真圓度0.00538 mm及真球度0.03749 mm，其結果可印證本量測系統具有良好的量測精度，可實際應用於五軸CNC工具機進行機上量測。

This study mainly focuses on the TS740 touch trigger probe and LK-G80 reflective distant sensors integrated on five-axis CNC machine with Heidenhain controller for in-process measurement, and investigation on the geometric error and position error of the measurement on the machine. After verifying the accuracy of the measurement, the developed system can be used to measure objects of irregular geometry and regular geometry, and is suitable for the comprehensive measurement of a workpiece on 5-axis CNC machines.
By integrating the probe via software and hardware with a 5-axis CNC machine, and a set of measurement data analysis program has been written in MATLAB software. The developed program can be analyze the coordinate data, to obtain the geometric error or position error. An artefact combining the ISO cutting test piece and the free-form surface was used as measurement targets in this study. Concerning the measuring path configuration, the non-contact measurement device used the positive Z-direction measurement configuration and the contact measurement device used the surface normal vector measurement configuration.
This study compared the CMM measurement and the in-process measurement for error comparison analysis. The maximum error for the freeform surface was 0.0485 mm, and the maximum error for the geometrical tolerance of the regular shape measurement was follows: straightness 0.00406 mm, flatness 0.00068 mm, roundness 0.00538 mm and sphereness 0.03749 mm. Base on the measurement result, it showed that the measurement system was with good accuracy to carry out the in-process measurement.

摘要 I
Abstract II
誌謝 IV
目錄 V
圖索引 VIII
表索引 XI
第一章 緒論 1
1.1研究動機與目的 1
1.2 文獻回顧 2
1.3研究方法與論文架構 8
第二章　量測原理與設備之介紹 10
2.1接觸式與非接觸式探頭介紹與比較 10
2.1.1接觸式探頭 10
2.1.2 非接觸式探頭 12
2.2雷射位移計工作原理 13
2.3觸發式探頭量測原理 15
2.4實驗設備 20
2.4.1五軸CNC加工機(Quaser UX300) 20
2.4.2 CNC三次元座標量測儀(Crysta Apex C 544) 22
2.4.3觸發式探頭(Heidenhain TS740) 23
2.4.4雷射位移計(Keyence LK-G80) 24
第三章　量測系統之整合與幾何公差演算法 25
3.1接觸式量測系統整合 27
3.2非接觸式量測系統整合 29
3.3幾何公差定義與分析方法 32
3.3.1真直度 32
3.3.2真平度 33
3.3.3真圓度 35
3.3.4真球度 40
第四章 實驗流程 42
4.1 量測系統校正 43
4.1.1雷射位移計校正 43
4.1.2觸發式探頭校正 46
4.2量測載具製作 50
4.3標準球真圓度檢測 51
4.4歪斜面上ISO切削測試件之檢測 52
4.5歪斜面上四凸一凹自由曲面之檢測 55
第五章 實驗結果 58
5.1 加工誤差比對 58
5.1.1 四凸一凹自由曲面加工誤差 58
5.1.2 ISO切削測試標準件幾何誤差 60
5.2量測誤差比對 64
5.2.1標準球量測誤差比對 64
5.2.2四凸一凹自由曲面非接觸式量測誤差比對 65
5.2.3四凸一凹自由曲面接觸式量測誤差比對 67
5.2.4 ISO切削件測試標準件量測誤差比對 70
5.3 逆向工程應用 79
第六章 結論與未來展望 80
6.1 結論 80
6.2未來研究方向 81
參考文獻 83
附錄一 87
附錄二 92
附錄三 93
附錄四 94
附錄五 110
附錄六 120
附錄七 126

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