The Design and Implementation of a Dynamic Measurement System for a Large Gear Rotation Angle Based on an Extended Visual Field

High-precision measurement of large gear rotation angles is a critical technology in gear meshing-based measurement systems. To address the challenge of high-precision rotation angle measurement for large gear, this paper proposes a binocular vision method. The methodology consists of the following steps: First, sub-pixel edges of calibration circles on a 2D dot-matrix calibration board are extracted using edge detection algorithms to obtain pixel coordinates of the circle centers. Second, a high-precision calibration of the measurement reference plate is achieved through a 2D four-parameter coordinate transformation algorithm. Third, binocular cameras capture images of the measurement reference plates attached to large gear before and after rotation. Coordinates of the camera's field-of-view center in the measurement reference plate coordinate system are calculated via image processing and rotation angle algorithms, thereby determining the rotation angle of the large gear. Finally, a binocular vision rotation angle measurement system was developed, and experiments were conducted on a 600 mm-diameter gear to validate the feasibility of the proposed method. The results demonstrate a measurement accuracy of 7 arcseconds (7") and a repeatability precision of 3 arcseconds (3") within the 0-30° rotation range, indicating high accuracy and stability. The proposed method and system effectively meet the requirements for high-precision rotation angle measurement of large gear.