Development of a Real-Time Online Automatic Measurement System for Propeller Manufacturing Quality Control

The quality of machined marine propellers plays a critical role in underwater propulsion performance. Precision casting is the predominant manufacturing technique; however, deformation of wax models and rough blanks during manufacturing frequently cause deviations in the dimensions of final products and, thus, affect propellers’ performance and service life. Current inspection methods primarily involve using coordinate measuring machines and sampling. This approach is time-consuming, has high labor costs, and cannot monitor manufacturing quality in real-time. This study developed a real-time online automated measurement system containing a high-resolution CITIZEN displacement sensor, a four-degree-of-freedom measurement platform, and programmable logic controller-based motion control technology to enable rapid, automated measurement of blade deformation across the wax model, rough blank, and final product processing stages. The measurement data are transmitted in real time to a cloud database. Tests conducted on a standardized platform and real propeller blades confirmed that the system consistently achieved measurement accuracy to the second decimal place under the continual measurement mode. The system also demonstrated excellent repeatability and stability. Furthermore, the continuous measurement mode outperformed the single-point measurement mode. Overall, the developed system effectively reduces labor requirements, shortens measurement times, and enables real-time monitoring of process variation. These capabilities underscore its strong potential for application in the smart manufacturing and quality control of marine propellers.