Enhancing Laser Step Diagonal Measurement by Multiple Sensors for Fast Machine Tool Calibration

Dahlem, Philipp; Montavon, Benjamin; Peterek, Martin; Schmitt, Robert

doi:10.5604/01.3001.0012.0928

Cited by 4 publications

(2 citation statements)

References 8 publications

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“…Fully analyzing the geometry of CNC machine tools in an industrial setting is a nontrivial task. Current developments in measurement techniques and equipment [16,17] provide the end user with simpler and less time-consuming measurements. One such technique is the idea of measuring multiple possible geometry errors in a single motion -known as MultiDOF [18].…”

Section: Theory Of Operationmentioning

confidence: 99%

The Use of 3-DOF Laser Interferometer for Rapid Estimation of CNC Drives Settings

Budzyn,

Rzepka

2024

Journal of Machine Engineering

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Although machine geometry measurements are an important part of mechanical engineering, they alone do not deliver enough information to set up or verify a CNC machine. The behaviour of the machine controller and its drive control settings usually need to be at least checked and in many situations corrected. In this article, on the basis of a developed machine error model, we show that it is sufficient to use a laser interferometer with a straightness measurement module to gather enough information in a single measurement to verify axis geometry and, at the same time, proper settings of machine servo loop gain. The results obtained during dynamic diagonal measurement can then be used to directly amend the servo settings. We prove our assumption in a series of realworld measurements.

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Section: Theory Of Operationmentioning

confidence: 99%

The Use of 3-DOF Laser Interferometer for Rapid Estimation of CNC Drives Settings

Budzyn,

Rzepka

2024

Journal of Machine Engineering

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“…Scenarios of fast machine diagnostics and repeated measurements that are carried out by the machine operator itself and limit unproductive machine downtime will become more important. However, usually it may be more expensive than necessary to use measuring methods that are suitable for calibration measurements for this, even though there are also attempts for uniform measurements, e.g [8]. Suitable measuring methods to deliver statements for decision support must meet the following requirements for fast performance tests:…”

Section: Introductionmentioning

confidence: 99%

Fast evaluation of the volumetric motion accuracy of multi-axis machine tools using a Double-Ballbar

Kauschinger¹,

Friedrich²,

Rui-qing³

et al. 2020

Journal of Machine Engineering

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The proof of manufacturing accuracy requires continuous verification and crosscheck of the motion accuracy of machine tools. Machining in 5 to 6 axes intensifies the problem of measurement and evaluation of volumetric motion accuracy in up to 6 degrees of freedom (DOF) in the whole workspace. Although, there are many known, even standardized, measuring methods, they are either expensive, time-consuming, not applicable in an operational state of the machine under shop floor conditions, or their significance is limited to only 1 or 2 feed-axes. Appropriate methods to be run regularly, fast and cost-efficient by the machine operator as a performance test are still desired. The article presents a new approach that meets these requirements. It is based on a Double-Ballbar (DBB) with enlarged measuring range and volumetric measuring paths of up to 6 DOF with all feed-axes moving simultaneously during continuous measurement, instead of plane circular paths according to ISO 230-4. After an explanation of the proposed method, the developed DBB device is introduced, including its mechanical and sensor design, the data interface, and results of experimental investigations on the measuring accuracy. Furthermore, relevant problems regarding the design, optimization, and programming of appropriate 6 DOF measuring paths are discussed and experimental results are presented that show the advantage compared to other measuring paths.

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A Digital Perspective on Machine Tool Calibration

Montavon

Dahlem

Peterek

et al. 2020

IJAT

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Machine tool calibration and subsequent controller-based compensation are industrially established and research-intensive techniques used to monitor and increase the volumetric performance in high-precision manufacturing. Moreover, a variety of interim performance checks and integrated sensor approaches have been developed to predict volumetric performance degradation and avoid an economically undesirable downtime. However, the fragmentation of data acquisition and management limits the potential for additional insights with respect to the value creation based on existing methods in the field of machine tool calibration. The authors reviewed the former from the perspective of data sources according to the frequency of their contribution to the digital twin of a machine tool, adopting a digital view regarding machine tool calibration within the Internet of Production concept. The latter proposes a semantic separation of cyber physical production systems into four layers: data sources, data access and provisioning, storage and analytics, and user respective agent feedback. To achieve a common representation across different layers, devices, and industrial Internet protocols, a model-based abstraction layer is required, which must be compatible with existing standards within the field, e.g., the ISO 230 series. Utilizing different Internet of Production architectures and platforms, a multitude of parallel analytic applications and an evaluation of complex models are enabled owing to the availability of ample computing resources, among which the machine tool’s numerical controller takes the role of an edge-device injecting the feedback into the production process. A proof-of-concept of a digital approach to machine tool calibration data storage and processing was established based on the software prototype VoluSoft, which implements an ISO 230-1:2012 based abstraction layer in JavaScript Object Notation format, and an evaluation of the kinematic models to estimate the volumetric performance at the functional point. Apart from generating compensation tables, the results are used to project the expected deviation at the tool tip to the computer-aided design-model of a work piece, correlate the error motions using the temperature data acquired by integrated sensors, and estimate the contribution of the volumetric performance limitation to the uncertainty budget of on-machine measurements.

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Enhancing Laser Step Diagonal Measurement by Multiple Sensors for Fast Machine Tool Calibration

Cited by 4 publications

References 8 publications

The Use of 3-DOF Laser Interferometer for Rapid Estimation of CNC Drives Settings

The Use of 3-DOF Laser Interferometer for Rapid Estimation of CNC Drives Settings

Fast evaluation of the volumetric motion accuracy of multi-axis machine tools using a Double-Ballbar

A Digital Perspective on Machine Tool Calibration

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