Research on Laser On-Line Monitoring for Counter-Roller Spinning of Thin-Walled Cylindrical Parts

In order to achieve intelligent control of counter-roller spinning equipment and improve the accuracy of the counter-roller spinning forming of thin-walled cylindrical parts used in the aerospace field, a set of roller position monitoring and workpiece size online measurement system for full-electric servo vertical three counter-roller driving power spinning equipment is designed according to the laser displacement sensor ranging principle. Different installation positions were determined according to the measurement objects of each laser displacement sensor, and the analog voltage signals of multiple groups of laser displacement sensors were obtained through the data acquisition card, and the relationship between the voltage signals of each sensor and the actual displacement was calculated, thereby monitoring the real-time position of each moving component online. In order to test the reliability of the on-line monitoring system, a 500 mm diameter, 10 mm wall thickness 2219 Al alloy cylindrical billet was formed to 3.5 mm thickness on the equipment. The cylindrical part formed with the aid of this system has good dimensional accuracy, and its radius deviation, roundness error, and wall thickness difference are 0.2977 mm, 0.2402 mm, and 0.05 mm, respectively, which are reduced by 94.7%, 95.4%, and 28.5% compared to the cylindrical billet, respectively.