A New Image Grating Sensor for Linear Displacement Measurement and Its Error Analysis.

To improve the accuracy of the current vision-based linear displacement measurement in a large range, a new type of linear displacement sensing system, namely, image grating, is proposed in this paper. The proposed system included a patterned glass plate attached to the moving object and an ultra-low distortion lens for high-accuracy image matching. A DFT local up-sampling phase correlation method was adopted to obtain the sub-pixel translation of the patterns onto the target plate. Multiple sets of stripe patterns with different designs were located on the glass plate to expand the measurement range, based on the principle of phase correlation. In order to improve the measurement accuracy, the main errors of the image grating system were analyzed, and the nonlinear error compensation was completed based on the dynamic calibration of the pixel equivalent. The measurement results, after the error compensation, showed that the total error of the proposed system was less than 2.5 µm in the range of 60 mm, and the repeatability was within 0.16 µm, as quantified by standard deviation.

Online Tool Condition Monitoring Based on Parsimonious Ensemble.

Existing methodologies for tool condition monitoring (TCM) still rely on batch approaches which cannot cope with a fast sampling rate of a metal cutting process. Furthermore, they require a retraining process to be completed from scratch when dealing with a new set of machining parameters. This paper presents an online TCM approach based on Parsimonious Ensemble+ (pENsemble+). The unique feature of pENsemble+ lies in its highly flexible principle where both the ensemble structure and base-classifier structure can automatically grow and shrink on the fly based on the characteristics of data streams. Moreover, the online feature selection scenario is integrated to actively sample relevant input attributes. This paper presents advancement of a newly developed ensemble learning algorithm, pENsemble, where the online active learning scenario is incorporated to reduce the operator's labeling effort. The ensemble merging scenario is proposed which allows reduction of ensemble complexity while retaining its diversity. Experimental studies utilizing two real-world manufacturing data streams: 1) metal turning and 2) 3-D-printing processes and comparisons with well-known algorithms were carried out. Furthermore, the efficacy of pENsemble+ was examined using benchmark concept drift data streams. It has been found that pENsemble+ incurs low structural complexity and results in a significant reduction of the operator's labeling effort.

Development of an Image Grating Sensor for Position Measurement.

In this research paper, a precision position-measurement system based on the image grating technique is presented. The system offers a better robustness and flexibility for 1D position measurement compared to a conventional optical encoder. It is equipped with an image grating attached to a linear stage as the target feature and a line scan camera as the stationary displacement reader. By measuring the position of the specific feature in the image and applying a subpixel image registration method, the position of the linear stage can be obtained. In order to improve the computational efficiency, the calculations for pattern correlation and subpixel registration are performed in the frequency domain. An error compensation method based on a lens distortion model is investigated and implemented to improve the measurement accuracy of the proposed system. Experimental data confirms the capability of the developed image grating system as ±0.3 µm measurement accuracy within a 50 mm range and ±0.2 µm measurement accuracy within a 25 mm range. By applying different optics, the standoff distance, measurement range, and resolution can be customized to conform to different precision measurement applications.

A Non-Contact Measuring System for In-Situ Surface Characterization Based on Laser Confocal Microscopy.

The characterization of surface topographic features on a component is typically quantified using two-dimensional roughness descriptors which are captured by off-line desktop instruments. Ideally any measurement system should be integrated into the manufacturing process to provide in-situ measurement and real-time feedback. A non-contact in-situ surface topography measuring system is proposed in this paper. The proposed system utilizes a laser confocal sensor in both lateral and vertical scanning modes to measure the height of the target features. The roughness parameters are calculated in the developed data processing software according to ISO 4287. To reduce the inherent disadvantage of confocal microscopy, e.g., scattering noise at steep angles and background noise from specular reflection from the optical elements, the developed system has been calibrated and a linear correction factor has been applied in this study. A particular challenge identified for this work is the in-situ measurement of features generated by a robotized surface finishing system. The proposed system was integrated onto a robotic arm with the measuring distance and angle adjusted during measurement based on a CAD model of the component in question. Experimental data confirms the capability of this system to measure the surface roughness within the Ra range of 0.2⁻7 µm (bandwidth λc/λs of 300), with a relative accuracy of 5%.

Frequency Domain Analysis of Sensor Data for Event Classification in Real-Time Robot Assisted Deburring.

Process monitoring using indirect methods relies on the usage of sensors. Using sensors to acquire vital process related information also presents itself with the problem of big data management and analysis. Due to uncertainty in the frequency of events occurring, a higher sampling rate is often used in real-time monitoring applications to increase the chances of capturing and understanding all possible events related to the process. Advanced signal processing methods are used to further decipher meaningful information from the acquired data. In this research work, power spectrum density (PSD) of sensor data acquired at sampling rates between 40-51.2 kHz was calculated and the corelation between PSD and completed number of cycles/passes is presented. Here, the progress in number of cycles/passes is the event this research work intends to classify and the algorithm used to compute PSD is Welch's estimate method. A comparison between Welch's estimate method and statistical methods is also discussed. A clear co-relation was observed using Welch's estimate to classify the number of cycles/passes. The paper also succeeds in classifying vibration signal generated by the spindle from the vibration signal acquired during finishing process.

A direct method to solve optimal knots of B-spline curves: An application for non-uniform B-spline curves fitting.

B-spline functions are widely used in many industrial applications such as computer graphic representations, computer aided design, computer aided manufacturing, computer numerical control, etc. Recently, there exist some demands, e.g. in reverse engineering (RE) area, to employ B-spline curves for non-trivial cases that include curves with discontinuous points, cusps or turning points from the sampled data. The most challenging task in these cases is in the identification of the number of knots and their respective locations in non-uniform space in the most efficient computational cost. This paper presents a new strategy for fitting any forms of curve by B-spline functions via local algorithm. A new two-step method for fast knot calculation is proposed. In the first step, the data is split using a bisecting method with predetermined allowable error to obtain coarse knots. Secondly, the knots are optimized, for both locations and continuity levels, by employing a non-linear least squares technique. The B-spline function is, therefore, obtained by solving the ordinary least squares problem. The performance of the proposed method is validated by using various numerical experimental data, with and without simulated noise, which were generated by a B-spline function and deterministic parametric functions. This paper also discusses the benchmarking of the proposed method to the existing methods in literature. The proposed method is shown to be able to reconstruct B-spline functions from sampled data within acceptable tolerance. It is also shown that, the proposed method can be applied for fitting any types of curves ranging from smooth ones to discontinuous ones. In addition, the method does not require excessive computational cost, which allows it to be used in automatic reverse engineering applications.