Research on the mechanism of interruption in five-axis sweep scanning measurement

Sweep scanning, an emerging contact measurement method based on five-axis coordinate measurement machines, has garnered significant attention in the measurement of complex geometries due to its high-speed capabilities and operational flexibility. However, one of the major challenges limiting its performance is the occurrence of frequent non-interference interruptions during the scanning process, which negatively impacts measurement efficiency. This study focuses on investigating the underlying causes of these interruptions by analyzing the motion patterns of the stylus and the deflection mechanism induced by external forces. The concepts of regulation differential angle (RDA), defined as the angle between the stylus deformation direction and the deflection control vector, is proposed to explain the interruption mechanism. When RDA exceeds 60°, the likelihood of measurement interruption increases significantly, providing a critical threshold for system performance. Based on the concept, a model is developed to describe the interruption phenomenon, and its effectiveness is evaluated. The study identifies the critical conditions under which interruptions occur during sweep scanning and provides insight into the role of frictional forces in introducing asymmetry to the process. To our knowledge, this work represents the first comprehensive analysis of the interruption mechanism in sweep scanning. Experimental validation was conducted on several surface types, including planar, spherical, and aero-engine blade LEs, which confirms the existence of the regulation mechanism and supports the model’s accuracy and reliability in explaining the interruption phenomenon.