Error Modeling and Path Planning for Freeform Surfaces by Laser Triangulation On-Machine Measurement

On-machine measurement (OMM) is increasingly used to inspect freeform surfaces without unloading the workpiece from the machine tool. Compared to the mechanical probe deployed in many OMM processes, a laser displacement sensor has its advantage of high scanning efficiency. However, the accuracy has been a bottleneck limiting its application in precision inspection, due to the lack of a rigorously planned path. In this work, an error compensation model is established and verified considering laser triangulation error, misalignment from calibration, tooling error, and preevaluated error. Essentially, error modeling contributes to improve the measurement accuracy of laser triangulation OMM (LTOMM). After understanding these errors, a reliable measuring path is crucial to maintain the given accuracy of LTOMM. This path generated is capable of minimizing the measurement time at a given accuracy constraint. In a particular case study, a turbine blade surface was inspected using LTOMM following generated path against a built-in probe. The measurement time was reduced by 77.4% for a constraining accuracy of ±10 μ\textm. The time could be further reduced by 38.6%, for a constraining accuracy of ±13 μ\textm. This study has demonstrated that LTOMM could potentially replace the on-machine probe during measurement of freeform surfaces, toward more efficient industrial applications in the future.