锥孔测量——用基于光纤的光学 3D 测量法代替发蓝测量仪

Tapered hole measurement – replacing bluing gauges with fiber-based optical 3D metrology

锥孔测量——用基于光纤的光学 3D 测量法代替发蓝测量仪

Measuring tapered holes is a preoccupation in many high-precision industries. One traditional approach for inspecting tapered holes involves the use of bluing plug gauges.

测量锥形孔是许多高精度行业的当务之急。检测锥形孔的一种传统方法涉及使用蓝塞量规。

This article briefly describes the bluing process and then looks at an alternative approach for tapered hole inspection – one that is more automation-friendly and that provides high-precision measurements that go way beyond GO/NO-GO capability.

本文简要介绍了发蓝工艺，然后介绍了另一种锥形孔检测方法——一种自动化程度更高的方法，可提供远远超出 GO/NO-GO 能力的高精度测量。

What is the bluing process?

什么是发蓝工艺？

The bluing (or blue check) process checks the contact area between a male master taper a tapered hole, which is considered the female part of a mating taper fit.

发蓝（或蓝检）工艺检查外螺纹主锥与锥孔之间的接触面积，该锥孔被认为是配合锥形配合的内螺纹部分。

How bluing works in 3 steps

发蓝的工作原理分为 3 个步骤

A male master taper is covered
with a thin coat of
Engineer’s blue
(Prussian blue pigment mixed with oil).

一个阳主锥上覆盖着一层薄薄的工程师蓝（普鲁士蓝颜料与油混合）。

The male master taper is pressed into the tapered hole.

阳主锥被压入锥形孔。

The master taper is withdrawn and inspected
for indications of too much or too little taper and for indications of defects or out-of-roundness.

取出主锥度并检查锥度过多或过少的迹象以及缺陷或圆度不齐的迹象。

GO/NO-GO decision:
In areas where the master taper and the tapered hole surfaces came in contact, the blue ink is fully or partially transferred to the inside diameter (ID) of the hole.

The estimated percentage of ink that transferred indicates how true to form the tapered bore is.
Operators need considerable experience to be able to estimate the percent contact of the surfaces and judge whether the contact is adequate (e.g., 80% or 90% contact may be required for a GO answer).

GO/NO-GO 决定：在标准锥度和锥孔表面接触的区域，蓝色墨水全部或部分转移到孔的内径 (ID)。转移的墨水的估计百分比表示形成锥形孔的真实程度。操作员需要相当丰富的经验才能估计表面的接触百分比并判断接触是否足够（例如，GO 答案可能需要 80% 或 90% 的接触）。

Bluing process – tapered hole measurement with bluing gauges – in 3 basic steps.

发蓝工艺——使用发蓝量规测量锥孔——分3个基本步骤。

Example application: blue pins for inspection of tapered drill holes in assembly

示例应用：用于检查装配中锥形钻孔的蓝针

Blue pins
are small bluing gauges used to inspect tapered holes just several mm in diameter.

蓝针是用于检查直径只有几毫米的锥形孔的小型蓝规。

In some high-precision assembly plants, blue pins are used to inspect the quality of tapered holes that are drilled and reamed to accommodate specialty bolts (e.g., tapered shank bolts).
In such holes, blue pins help identify defects such as out-of-round ID, cracks, burrs, gaps between drilled layers, or the approximate percentage of bearing surface.

在一些高精度装配厂中，蓝针用于检查钻孔和铰孔的锥孔质量，以适应特殊螺栓（例如，锥形杆螺栓）。在此类孔中，蓝色销有助于识别缺陷，例如圆外内径、裂纹、毛刺、钻孔层之间的间隙或轴承表面的大致百分比。

How well does bluing work?

发蓝效果如何？

The bluing process provides a GO/NO-GO answer for tapered hole inspection.
It is used when the general fit of the male taper into the tapered hole matters but if exact measurements are not important.

发蓝工艺为锥形孔检测提供了可行/不可行的答案。当外螺纹与锥形孔的总体配合很重要但精确测量并不重要时，可以使用它。

The answer to “How well does bluing works?” depends on the context. Here are some benefits and shortcomings of the bluing method, which remains useful and relevant for taper hole inspection in small-volume operations:

“蓝化效果如何？”的答案
取决于上下文。以下是蓝化方法的一些优点和缺点，这些方法对于小批量操作中的锥孔检测仍然有用且相关：

Benefits of bluing process:
Simple GO/NO-GO;
economical in terms of equipment for small volume operations

发蓝工艺的优点：简单的 GO/NO-GO；在设备方面经济的小批量操作

Disadvantages:
Manual technique; slow and labour-intensive; gives no quantitative measurement; evaluation is subjective – operator experience and technique affect the coverage estimation.

缺点：手工技术；缓慢且劳动密集型；没有给出定量测量；评估是主观的——操作员的经验和技术会影响覆盖范围的估计。

Beyond GO/NO-GO what other aspects of tapered holes can be useful to measure?

除了 GO/NO-GO 之外，锥孔还有哪些其他方面可用于测量？

Many high-precision part manufacturers require more detailed and precise measurements than those available with the bluing method.

许多高精度零件制造商需要比使用发蓝方法进行的测量更详细且精确的测量。

A good start are GD&T (geometric dimensioning and tolerancing) parameters such as diameter measurements, taper angle, depth and conicity.

一个好的开端是 GD&T（几何尺寸和公差）参数，如直径测量、锥角、深度和锥度。

More advanced parameters can include location and geometry of inner features (e.g. cross-holes) or concentricity of the tapered hole with respect to a bore that leads to it.

更高级的参数可以包括内部特征（例如交叉孔）的位置和几何形状或锥形孔相对于通向它的孔的同心度。

Other aspects that can be measured are taper ID roughness, chatter, or defects such as gaps, burrs or cracks.

可以测量的其他方面包括锥度内径粗糙度、颤振或间隙、毛刺或裂纹等缺陷。

Critical tapered hole measurements may include taper depth, diameter, taper angle, conicity, concentricity with other features, roughness, chatter, defects, and more.

关键的锥形孔测量可能包括锥度深度、直径、锥角、锥度、圆度，与其他特征的同心度、粗糙度、颤振、缺陷等。

Extra demands of more advanced manufacture facilities

更先进的制造设施的额外需求

Requirements for tapered hole inspection also increasingly include empirical (rather than subjective) measurements and automation of tapered hole measurements. For instance, high-precision assembly lines with robotized drill-and-fill fastening processes often require:

锥孔检测的要求也越来越多地包括经验（而不是主观）测量和锥孔测量的自动化。例如，采用自动化钻孔和填充紧固工艺的高精度装配线通常需要：

Fully automated GO/NO-GO inspection of drilled fastener holes

紧固件钻孔的全自动 GO/NO-GO 检查

Precise and quantified hole ID and countersink measurements for analysis and logging

用于分析和记录的精确和量化的孔 ID 和埋头孔测量

Rapid measurement analysis that can be fed back into the quality control process loop.

可以反馈到质量控制过程循环中的快速测量分析。

For these kinds of requirements, manufacturers look for more advanced measurement approaches. And NOVACAM optical metrology systems often fit the bill.

对于这些类型的要求，制造商寻求更先进的测量方法。NOVACAM 光学计量系统通常符合要求。

Optical fiber-based system for taper hole measurement

基于光纤的锥孔测量系统

Novacam offers three non-contact 3D measurement systems for tapered hole measurement: the
BOREINSPECT system, the
TUBEINSPECT system
and the
SURFACEINSPECT system. All three are optical and fiber-based and offer manufacturers an advanced set of capabilities for tapered hole measurement. The choice of system depends on the application.

Novacam 提供三种用于锥形孔测量的非接触式 3D 测量系统：BOREINSPECT 系统、TUBEINSPECT 系统和SURFACEINSPECT 系统。这三者都是基于光学和光纤的，为制造商提供了一套先进的锥形孔测量功能。系统的选择取决于应用。

In this article, we look at the BOREINSPECT system, which would be the system of choice for the above example of measuring tapered holes in robot drill-and-fill applications.

在本文中，我们将介绍 BOREINSPECT 系统，该系统将成为上述机器人钻填应用中锥形孔测量示例的首选系统。

The BOREINSPECT system uses a rotational scanning probe to easily reach inside each tapered hole to acquire its ID. As illustrated, scanning is done in a point-by-point manner (at a rate of up to 100,000 3D points per second).
Scan pathways can be linear, circular, spiral, or a combination thereof.

BOREINSPECT 系统使用旋转扫描探头轻松到达每个锥形孔内部以获取其内径。如图所示，扫描是以逐点方式完成的（速度高达每秒 100,000 个 3D 点）。扫描路径可以是线性的、圆形的、螺旋形的或其组合。

Tapered hole measurement with optical fiber-based 3D metrology – in 2 steps

使用基于光纤的3D计量技术进行锥孔测量 – 分为两步

Once the 3D point cloud is acquired, an industry standard metrology software (PolyWorks^TM
Inspector) is used to obtain the required tapered hole measurements.

获取 3D 点云后，使用行业标准计量软件 (PolyWorks
^TM
Inspector) 获得所需的锥孔测量值。

The design of the BOREINSPECT system probe enables measurements in almost any plant environment:

BOREINSPECT 系统探头的设计可在几乎任何工厂环境中进行测量：

The small and fiber-based probe can be integrated with precision stages, robots or gantries.

基于光纤的小型探头可以与精密平台、机器人或台架集成。

As an end-effector on a robot head, the probe alternates with drill end-effectors, and provides ID measurements regardless of hole location or orientation.

作为机器人头部的末端执行器，探头与钻头末端执行器交替使用，并提供内径测量，而无论孔的位置或方向如何。

The probe measurement is immune to ambient lighting and air perturbation. The probes can measure even in hostile environments, featuring extreme temperatures, pressures, or with radiation.

探头测量不受环境照明和空气扰动的影响。这些探头甚至可以在极端温度、压力或辐射的恶劣环境中进行测量。

The hole ID measurements are typically forwarded to process control software, so that real-time feedback is provided on drilling, grinding, or other tapered hole machining processes.

孔内径的测量值通常被转发到过程控制软件，以便在钻孔、磨削或其他锥形孔加工过程中提供实时反馈。

Benefits of BOREINSPECT system for taper hole inspection

BOREINSPECT 系统用于锥孔检测的优势

The BOREINSPECT system provides many benefits:

BOREINSPECT 系统具有许多优势：

Micron-precision of measurement

微米级的测量精度

Non-contact measurement – no consumables or stoppages to change probes

非接触式测量——无需耗材或停止更换探头

Versatile installation & integration options for fully automated measurement of tapered and other holes.
Blind holes and hard-to-reach holes included.

用于锥孔和其他孔的全自动测量的多功能安装和集成选项。包括盲孔和难以触及的孔。

100 kHz scanning speed to enable 100% inspection

100 kHz 扫描速度可实现100%检测

Capabilities to provide quick visual comparison (deviation map) of the acquired ID measurements to pre-specified tolerances or to the CAD of the part

能够将获取的内径测量值与预先指定的公差或零件的CAD进行快速视觉比较（偏差图）

Wide range of
measurements in addition to GO/NO-GO, with the same probe:

除了GO/NO-GO之外的广泛范围测量，使用相同的探头：

Geometry: Diameters of the taper hole, taper angle, depth of hole, conicity, axial straightness, ovality, etc.

几何形状：锥孔直径、锥角、孔深、锥度、轴向直线度、椭圆度等。

Location of internal features

内部特征的位置

Concentricity with other features (e.g., bore leading to tapered chamfer)

与其他特征的同心度（例如，导致锥形倒角的孔）

Defects (e.g., burrs, patterns of rifling from drill bit, cracks, etc.)

缺陷（例如，毛刺、钻头上的膛线、裂纹等）

Waviness and roughness (axial
or
circumferential)

波度和粗糙度（轴向或圆周）

Chatter.

颤振。

Tapered interior of precision wire-drawing die. The acquired 3D point cloud can be automatically analyzed to measure included angles, lengths of different ID sections, roughness profiles, chatter, defects, etc.

精密拉丝模具的锥形内部。获取的 3D 点云可以自动分析，测量不同内径截面的夹角、长度、粗糙度、颤振、缺陷等。

What about taper hole measurement in other industries?

其他行业的锥孔测量呢？

Each machining and inspection process is unique.
For micron-precision tapered hole measurements, Novacam provides 3D metrology solutions in:

每个加工和检查过程都是独一无二的。对于微米精度的锥形孔测量，Novacam 在以下方面提供3D计量解决方案：

Aerospace: aircraft
fastener holes

航空航天：飞机紧固件孔

Automotive: tapered engine shaft couplings, pitman arms, taper bushings, nozzle seats in fuel injectors, raceways of tapered roller or ball bearings

汽车：锥形发动机联轴器、连杆臂、锥形衬套、喷油器中的喷嘴座、锥形滚柱或滚珠轴承的滚道

Die and Mold measurements
– high-precision dies with tapered holes, wire-drawing dies, mold cavities

模具测量——带锥孔的高精度模具、拉丝模具、模具型腔

Medical instrumentation: orthopedic device tapers

医疗器械：骨科器械锥度

Nuclear: reactor tubing

核：反应堆管

and more.

和更多。

An alternative recipe for measuring and analyzing the above precision die. 4 linear profiles of the tapered interior and one dense spiral profile of the middle cylindrical section can provide adequate 3D data for many measurements.

用于测量和分析上述精密模具的替代方法。锥形内部的4个线性轮廓和中间圆柱部分的密集螺旋轮廓可以为许多测量提供足够的 3D 数据。

文件：AN-THICKNESS-1.2（2021-06-03）

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