A simple method for simultaneously measuring the 6DOF geometric motion errors of the linear guide was proposed. The mechanisms for measuring straightness and angular errors and for enhancing their resolution are described in detail. A common-path method for measuring the laser beam drift was proposed and it was used to compensate the errors produced by the laser beam drift in the 6DOF geometric error measurements. A compact 6DOF system was built. Calibration experiments with certain standard measurement meters showed that our system has a standard deviation of 0.5 $\mu m$ in a range of ± 100 $\mu m$ for the straightness measurements, and standard deviations of 0.5$"$, 0.5$"$, and 1.0$"$ in the range of ± 100$"$ for pitch, yaw, and roll measurements, respectively.

A novel method for simultaneously measuring six degree-of-freedom (6DOF) geometric motion errors is proposed in this paper, and the corresponding measurement instrument is developed. Simultaneous measurement of 6DOF geometric motion errors using a polarization maintaining fiber-coupled dual-frequency laser is accomplished for the first time to the best of the authors’ knowledge. Dual-frequency laser beams that are orthogonally linear polarized were adopted as the measuring datum. Positioning error measurement was achieved by heterodyne interferometry, and other 5DOF geometric motion errors were obtained by fiber collimation measurement. A series of experiments was performed to verify the effectiveness of the developed instrument. The experimental results showed that the stability and accuracy of the positioning error measurement are 31.1 nm and 0.5 μm, respectively. For the straightness error measurements, the stability and resolution are 60 and 40 nm, respectively, and the maximum deviation of repeatability is ± 0.15 μm in the x direction and ± 0.1 μm in the y direction. For pitch and yaw measurements, the stabilities are 0.03″ and 0.04″, the maximum deviations of repeatability are ± 0.18″ and ± 0.24″, and the accuracies are 0.4″ and 0.35″, respectively. The stability and resolution of roll measurement are 0.29″ and 0.2″, respectively, and the accuracy is 0.6″.

A novel method for simultaneously directly measuring six-degrees-of-freedom (6DOF) geometric motion errors of CNC machine tools was proposed, and a corresponding measurement system was developed. This method can not only be applied for measuring a linear axis, but also for a rotary axis. A single-mode fiber was used to separate the measuring unit from the laser source in order to ensure system thermal stability and measurement accuracy. The method has the advantages of high efficiency and good accuracy, and requires no complicated decoupling calculation. The positioning error of the linear axis and radial motion error of the rotary axis are measured by laser interferometry and other 5DOF geometric motion errors by laser collimation. A series of experiments were performed to verify the feasibility and effectiveness of the developed measurement system.

At present, the method of two-dimensional image recognition is mainly used to detect the abnormal fastener in the rail-track inspection system. However, the too-tight-or-too-loose fastener condition may cause the clip of the fastener to break or loose due to the high frequency vibration shock, which is difficult to detect from the two-dimensional image. In this practical application background, 3D visual detection technology provides a feasible solution. In this paper, we propose a fundamental multi-source visual data detection method, as well as an accurate and robust fastener location and nut or bolt segmentation algorithm. By combining two-dimensional intensity information and three-dimensional depth information generated by the projection of line structural light, the locating of nut or bolt position and accurate perception of height information can be realized in the dynamic running environment of railway. The experimental results show that the static measurement accuracy in the vertical direction using the structural light vision sensor is 0.1 mm under the laboratory condition, and the dynamic measurement accuracy is 0.5 mm under the dynamic train running environment. We use dynamic template matching algorithm to locate fasteners from 2D intensity map, which achieves 99.4% accuracy, then use the watershed algorithm to segment the nut and bolt from the corresponding depth image of located fastener. Finally, the 3D shape of the nut and bolt is analyzed to determine whether the nut or bolt height meets the local statistical threshold requirements, so as to detect the hidden danger of railway transportation caused by too loose or too tight fasteners.

Error compensation has become an important means of improving the manufacturing and processing accuracy of computer numerical control (CNC) machine tools. Quick and precise measurement of the various geometric motion errors (GMEs) of CNC machine tools is crucial. We propose a novel laser method for the efficient and direct high-precision measurement of the 21 GMEs of a three-axis CNC machine tool, or three linear axes of a five-axis tool. A corresponding system was developed, comprising a fiber-coupled laser unit, sensor head, target unit, and beam-steering unit. The beam-steering unit was designed to perform high-accuracy 90° rotation of the measuring beam, and the target unit was designed to be sensitive to 18 GMEs of the three linear axes. Stability, repeatability, and comparison experiments were conducted to verify the performance of the proposed system. The results showed that the stability of the position error measurement is ± 6.3 nm. For straightness error measurement, the stability, repeatability error, and residual are within ± 60.3 nm, ± 0.5 μm, and ± 0.7 μm, respectively. These are within ± 0.12 arcsec, ± 0.5 arcsec, and ± 0.5 arcsec for the pitch and yaw measurements, and within ± 0.37 arcsec, ± 1.5 arcsec, and ± 1.0 arcsec for the roll measurements, respectively. For squareness error measurement, the repeatability error and residual are within ± 0.6 arcsec and ± 1.6 arcsec, respectively. Compared with a laser interferometer, the proposed system can measure the 21 GMEs of a three-axis machine tool with one-step installation. Without accuracy loss, the measurement efficiency is approximately 45 times higher than that of a laser interferometer, thus providing a new quick and accurate measurement method of GMEs and error compensation of CNC machine tools.

The rotary axis is the basis for rotational motion. Its motion errors have critical effects on the accuracy of the related equipment, such as a five-axis computer numerical control machine tool. There are several difficult problems in the implementation of high-precision and fast measurement of the multi-degree-of-freedom motion errors of a rotary axis. In this paper, a novel method for the simultaneous measurement of five-degree-of-freedom motion errors of a rotary axis is proposed, which uses a single-mode fiber-coupled laser with a full-circle measuring range. It has the advantages of high efficiency, low cost, and it requires no decoupling calculation. An experimental system was built and a series of experiments were performed. The standard deviation of stability for 60 min of the five-degree-of-freedom measurement is 0.05 arcsec, 0.06 arcsec, 0.04 μm, 0.03 μm, and 0.19 arcsec, respectively. The repeatability deviation of measuring an indexing table is ± 3.4 arcsec, ± 4.6 arcsec, ± 2.6 μm, ± 2.4 μm, and ± 3.2 arcsec. The maximum deviation of comparison is 3.9 arcsec and 3.2 arcsec. These results demonstrate the effectiveness of the proposed method; thus, a new approach of simultaneous measurement of the multi-degree-of-freedom motion errors of a rotary axis is provided.