Laser R-Test for Angular Positioning Calibration and Compensation of the Five-Axis Machine Tools

Tran, Cao-Sang; Hsieh, Tung-Hsien; Jywe, Wen-Yuh

doi:10.3390/app11209507

Cited by 8 publications

(7 citation statements)

References 11 publications

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“…Moreover, with the same setup method, this system and method can complete multiple error detections, including angular positioning errors [13], eccentricity errors [11], and wobble errors, by simply using different paths. This greatly reduces the setup time for future users, enhancing its commercial applicability.…”

Section: Discussionmentioning

confidence: 99%

“…This greatly reduces setup and measurement time, and the non-contact nature of the system minimizes the chance of collisions.Soichi Ibaraki's research introduces an enhanced non-contact R-test by using three Laser Triangulation displacement sensors [12]. This study focuses on a new algorithm and laser sensor uncertainties to efficiently calibrate errors in five-axis machine tools, comparing its performance with traditional methods.As relevant scholars began to analyze the acquired measurement error trajectories, they often used mathematical methods to analyze PIGEs and PDGEs errors, aiming to improve the simultaneous five-axis trajectory errors and overall composite errors.Hao Tran, CS and Hsieh, TH proposed a method for analyzing rotary axis angular positioning errors [13]. This method primarily uses the Cosine theorem in a Cartesian system to address concentricity issues.…”

Section: Research Motivation and Backgroundmentioning

confidence: 99%

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Geometric error compensation method using the Laser R-test

Hsieh,

JYWE,

ZENG

et al. 2023

Preprint

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Regarding the precision of the five-axis machine tool, it is found that 70% of its error is derived from the rotational axis PIGEs and PDGEs. At present, the measurement of these errors is required to be conducted by instruments such as interferometers, DBB, IBS, etc., which are considered expensive and time-consuming. In this research, the development of a contactless calibration tool system, which is designed to measure all 43 items of PIGEs and PDGEs in the five-axis machine tool, is pursued. The calibration tool, named “Laser R-Test” and developed since 2000, is recognized as being capable of analyzing the eccentricity error (XOC,YOC,ZOA,YOA) and angular position error (ECC,EAA). Moreover, the five-axis simultaneous trajectory error can be measured. Through extensive research, it has been determined that the total error in a five-axis machine tool can be controlled to below 40 um after compensating for two error parameters. However, achieving a total error below \(\pm\)10 um remains elusive. This limitation is attributed to the presence of wobble error (such as AOC, BOC, AOB, COB) in the rotary axis orientation, and the analysis and compensation for the rotary axis have yet to be achieved. In this study, a methodology based on Laser R-test and Rodrigues' rotation formula was developed to establish a PIGEs error model. The path XYZ errors were obtained through a simplified path combined with the Laser R-Test. By having the XYZ errors from each point in the path inputted into the model, the current errors and compensation values of the machine tool were determined. The analysis and compensation of 8 PIGEs errors in the rotary axis were completed in 30 minutes using the inspection path. Ultimately, the system's compatibility with K1, K2, and K4 path tests, as prescribed by ISO-10791-6, was ensured, validating the compensation effects on various parameters. A precision below \(\pm\)10 um was achieved, and the inspection time was reduced by over 50%. Then, by integrating the results of previous related studies, this system and method can complete multiple error detections, including angular positioning errors [13], eccentricity errors [11], and wobble errors, by simply using different paths. This greatly reduces the setup time for future users, enhancing its commercial applicability.

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Section: Discussionmentioning

confidence: 99%

Section: Research Motivation and Backgroundmentioning

confidence: 99%

Geometric error compensation method using the Laser R-test

Hsieh,

JYWE,

ZENG

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…As relevant scholars began to analyze the acquired measurement error trajectories, they often used mathematical methods to analyze PIGEs and PDGEs, aiming to improve the simultaneous five-axis trajectory errors and overall composite errors. Tran and Hsieh proposed a method for analyzing rotary axis angular positioning errors [12]. This method primarily uses the cosine theorem in a Cartesian system to address concentricity issues.…”

Section: Research Motivation and Backgroundmentioning

confidence: 99%

Geometric error compensation method using the Laser R-test

Hsieh,

Jywe,

Zeng

et al. 2024

Int J Adv Manuf Technol

Self Cite

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Traditional methods for measuring geometric errors in machine tools, including interferometry and Double Ball Bar (DBB), are known to be expensive and time-intensive. Consequently, a non-contact calibration system called the “Laser R-test” has been developed. This innovative system is designed to measure both position-independent geometric errors (PIGEs) and position-dependent geometric errors (PDGEs) efficiently. Since its development in 2000, this tool has been instrumental in analyzing eccentricity errors, angular position errors, and simultaneous trajectory errors. Through extensive research, it has been determined that the total error in a five-axis machine tool can be controlled to below 40 µm after compensating for eccentricity parameters and angular position errors. However, reducing this error to below ± 10 µm is challenging, primarily due to wobble errors in the orientation of the rotary axis without compensating. In this study, a new methodology based on Laser R-test and Rodrigues’ rotation formula has been developed to establish a PIGE model of rotary axis. Based on the methodology, the 8 PIGEs can be analyzed by measuring 5 coordinate positions. The compensation of 8 PIGEs in the rotary axis is completed within 30 min using the inspection path. Compatibility with ISO-10791–6 standards for BK1, BK2, and BK4 path tests is confirmed, validating the compensation effects. A precision of below ± 10 µm is achieved, with inspection time reduced by over 50%. This system can complete multiple errors by simply using the different paths. This greatly reduces the setup time for future users, enhancing its commercial applicability.

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“…With the development of technology, more and more complex and accurate measuring devices are used. Many of the new devices require completely new calibration procedures [ 11 , 12 ]. On the other hand, work is still underway to improve the existing calibration methods [ 13 , 14 ].…”

Section: Introductionmentioning

confidence: 99%

Application of Multi-Criteria Optimization Methods in the Calibration Process of Digital Measuring Instruments

Klebba

Adamczyk

Wąż

et al. 2023

Sensors

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The article describes the use of multi-criteria optimization methods during the calibration of digital multimeters. Currently, calibration is based on a single measurement of a specific value. The aim of this research was to confirm the possibility of using a series of measurements in order to reduce the measurement uncertainty without significantly extending the calibration time. The automatic measurement loading laboratory stand used during the conducted experiments was essential to obtain results that allowed confirming the thesis. This article presents the applied optimization methods and the results of the calibration of sample digital multimeters obtained thanks to them. As a result of the research, it was found that the use of a series of measurements increased the accuracy of the calibration, reduced the measurement uncertainty, and shortened the calibration time compared to traditional methods.

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Laser R-Test for Angular Positioning Calibration and Compensation of the Five-Axis Machine Tools

Cited by 8 publications

References 11 publications

Geometric error compensation method using the Laser R-test

Geometric error compensation method using the Laser R-test

Geometric error compensation method using the Laser R-test

Application of Multi-Criteria Optimization Methods in the Calibration Process of Digital Measuring Instruments

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