Multisensor-integrated metrology for multi-scale geometric characterization of aeroengine rotor shafts: adaptive error compensation and industrial validation

Abstract

The rotary shaft is a critical component in aeroengines, serving to support transmission parts, transmit torque, and withstand loads. With the rapid advancement of the aviation industry, the precision requirements for shaft components have become increasingly stringent. Traditional measurement techniques often fall short in achieving high-precision and high-efficiency automated measurements. To address this challenge, this study develops a vertical digital measurement system for shafts. Leveraging advanced technologies such as machine vision, optical detection, and deep learning, the system employs a multi-sensor collaborative approach to investigate hardware design, error compensation, the implementation and application of various measurement techniques, and the development of measurement software. By analyzing hundreds of macro and micro characteristics of complex rotary shafts, the system achieves automated measurement with single clamping. The system features an axial measurement range of 1300 mm, a radial measurement range of 120 mm, a measurement cycle of less than 15 min, and achieves an expanded uncertainty of 1.2 µm for macro-contour profiling and ±1 µm for runout measurement.