Laser Interferometer Based Measurement for Positioning Error Compensation in Cartesian Multi-Axis Systems

Accuracy is one of the most important key indices to evaluate multi-axis systems’ (MAS’s) characteristics and performances. The accuracy of MAS’s such as machine tools, measuring machines and robots is adversely affected by various error sources, including geometric imperfections, thermal deformations, load effects, and dynamic disturbances. The increasing demand for higher dimensional accuracy in various industrial applications has created the need to develop cost-effective methods for enhancing the overall performance of these mechanisms. Improving the accuracy of a MAS by upgrading the physical structure would lead to an exponential increase in manufacturing costs without totally eliminating geometrical deviations and thermal deformations of MAS components. Hence, the idea of reducing MAS’s error by a software-based alternative approach to provide real-time prediction and correction of geometric and thermally induced errors is considered a strategic step toward achieving the full potential of the MAS. This paper presents a structured approach designed to improve the accuracy of Cartesian MAS’s through software error compensation. Four steps are required to develop and implement this approach: (i) measurement of error components using a multidimensional laser interferometer system, (ii) tridimensional volumetric error mapping using rigid body kinematics, (iii) volumetric error prediction via an artificial neural network model, and finally (iv) implementation of the on-line error compensation. An illustrative example using a bridge type coordinate measuring machine is presented.

Motion Error Compensation of Multi-legged Walking Robots

Existing errors in the structure and kinematic parameters of multi-legged walking robots,the motion trajectory of robot will diverge from the ideal sports requirements in movement.Since the existing error compensation is usually used for control compensation of manipulator arm,the error compensation of multi-legged robots has seldom been explored.In order to reduce the kinematic error of robots,a motion error compensation method based on the feedforward for multi-legged mobile robots is proposed to improve motion precision of a mobile robot.The locus error of a robot body is measured,when robot moves along a given track.Error of driven joint variables is obtained by error calculation model in terms of the locus error of robot body.Error value is used to compensate driven joint variables and modify control model of robot,which can drive the robots following control model modified.The model of the relation between robot＇s locus errors and kinematic variables errors is set up to achieve the kinematic error compensation.On the basis of the inverse kinematics of a multi-legged walking robot,the relation between error of the motion trajectory and driven joint variables of robots is discussed.Moreover,the equation set is obtained,which expresses relation among error of driven joint variables,structure parameters and error of robot＇s locus.Take MiniQuad as an example,when the robot MiniQuad moves following beeline tread,motion error compensation is studied.The actual locus errors of the robot body are measured before and after compensation in the test.According to the test,variations of the actual coordinate value of the robot centroid in x-direction and z-direction are reduced more than one time.The kinematic errors of robot body are reduced effectively by the use of the motion error compensation method based on the feedforward.

MODELING AND COMPENSATION TECHNIQUE FOR THE GEOMETRIC ERRORS OF FIVE-AXIS CNC MACHINE TOOLS

One of the important trends in precision machining is the development ofreal-time error compensation technique. The error compensation for multi-axis CNC machine tools isvery difficult and attractive. The modeling for the geometric error of five-axis CNC machine toolsbased on multi-body systems is proposed. And the key technique of the compensation―identifyinggeometric error parameters―is developed. The simulation of cutting workpiece to verify the modelingbased on the multi-body systems is also considered.

Modeling, identification and compensation for geometric errors of laser annealing table

In order to improve the process precision of an XY laser annealing table, a geometric error modeling, and an identification and compensation method were proposed. Based on multi-body system theory, a geometric error model for the laser annealing table was established. It supports the identification of 7 geometric errors affecting the annealing accuracy. An original identification method was presented to recognize these geometric errors. Positioning errors of 5 lines in the workspace were measured by a laser interferometer, and the 7 geometric errors were identified by the proposed algorithm. Finally, a software-based error compensation method was adopted, and a compensation mechanism was developed in a postprocessor based on LabVIEW. The identified geometric errors can be compensated by converting ideal NC codes to actual NC codes. A validation experiment has been conducted on the laser annealing table, and the results indicate that positioning errors of two validation lines decreased from ±37 μm and ±33 μm to ±5 μm and ±4.5 μm, respectively. The geometric error modeling, identification and compensation method presented in this work can be straightforwardly extended to any configurations of 2-dimensional worktable.

Geometric error measuring,modeling,and compensation for CNC machine tools:A review

Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.

Spatial phase-shifting interferometry with compensation of geometric errors based on genetic algorithm(Invited Paper)

We propose a novel spatial phase-shifting interferometry that exploits a genetic algorithm to compensate for geometric errors. Spatial phase-shifting interferometry is more suitable for measuring objects with properties that change rapidly in time than the temporal phase-shifting interferometry. However, it is more susceptible to the geometric errors since the positions at which interferograms are collected are different. In this letter, we propose a spatial phase-shifting interferometry with separate paths for object and reference waves. Also, the object wave estimate is parameterized in terms of geometric errors, and the error is compensated by using a genetic algorithm.

Active Error Compensating Welding Fixture System for Auto Body

The welding fixtures are the most important devices for an auto body welding assembly line. The current special fixtures used by many automotive manufactures are only fit for one or several specific welding processes, and the dimensional problem in the circle due to several variation sources accumulation has no adjustment. The active error compensating welding fixture system for auto body is designed and manufactured. The detecting model, coordinate transformation model, and adjusting model based on auto body coordinate system are presented. The dowel pin modular design is adopted in the structure of the fixture to suit different workpieces with some similar characteristics. The online detection and adaptive control system using eddy current sensors and adaptive adjusting devices is analyzed. Three kinds of the left rear wheel covers SGM60 are selected to test workpieces of the developed system, and the active error compensating experiments are performed in the lab for many times. Test results show the validity of mechanism reconfigurations, on-line detections and error compensations of the developed welding fixture.

Research on volumetric error compensation for NC machine tool based on laser tracker measurement

Error compensation is an effective method to improve the accuracy of NC machine tool.The compensation results are greatly affected by the error modeling and error measurement,so how to establish an accurate error model and accurately detect the geometric errors of machine tool are particularly important.In the paper,the volumetric error model of a multi-axis NC machine tool is established based on the multi-body system theory.The relative position deviations between the rotary axis and linear axis of the machine tool are considered in the modeling.To achieve quick and accurate detection,a laser tracker is based on the multi-station and time-sharing measurement principle to detect the geometric errors of machine tool,and each error of linear axis and rotary axis can be identified by this method.With the error model,error compensation can be carried out by modifying the machining process(G code),and the machining accuracy can be improved with the new G code.Experiment results show that the motion errors of a milling machine are significantly reduced after compensation,which verifies the effectiveness of compensation method.

ROBOT'S MOTION ERROR AND ONLINE COMPENSATION BASED ON FORCE SENSOR

Robot＇s dynamic motion error and on-line compensation based on multi-axis force sensor are dealt with.It is revealed that the reasons of the error are formed and the relations of the error are delivered.A motion equation of robot＇s termination with the error is established,and then,an error matrix and an error compensation matrix of the motion equation are also defined.An on-line error＇s compensation method is put forward to decrease the displacement error,which is a degree of millimeter,shown by the result of simulation of PUMA562 robot.

Embedded sensor system for five-degree-of-freedom error detection on machine tools

Any linear stage of machine tool has inherent six-degree-of-freedom(6-DOF)geometric errors.Its motion control system,however,has only the position feedback.Moreover,the feedback point is not the commanded cutting point.This is the main reason why the positioning error along each axis and the volumetric error in the working space are inevitable.This paper presents a compact 5-DOF sensor system that can be embedded in each axis of motion as additional feedback sensors of the machine tool for the detection of three angular errors and two straightness errors.Using the derived volumetric error model,the feedback point can be transferred to the cutting point.The design principle of the developed 5-DOF sensor system is described.An in-depth study of systematic error compensation due to crosstalk of straightness error and angular error is analyzed.A prototype has been built into a three-axis NC milling machine.The results of a series of the comparison experiments demonstrate the feasibility of the developed sensor system.

Modeling and verification of comprehensive errors of real-time wear-depth detecting for spherical plain bearing tester

Because of various error factors,the detecting errors in the real-time experimental data of the wear depth affect the accuracy of the detecting data.The self-made spherical plain bearing tester was studied,and its testing principle of the wear depth of the spherical plain bearing was introduced.Meanwhile,the error factors affecting the wear-depth detecting precision were analyzed.Then,the comprehensive error model of the wear-depth detecting system of the spherical plain bearing was built by the multi-body system theory(MBS).In addition,the thermal deformation of the wear-depth detecting system caused by varying the environmental temperature was detected.Finally,according to the above experimental parameters,the thermal errors of the related parts of the comprehensive error model were calculated by FEM.The results show that the difference between the simulation value and the experimental value is less than 0.005 mm,and the two values are close.The correctness of the comprehensive error model is verified under the thermal error experimental conditions.

圆结构光系统深孔圆度测量方法研究

圆结构光系统测量深孔(通孔)圆度时存在激光器、相机和深孔难以保持平行或同轴的问题,导致无法测量准确的圆截面,从而产生系统误差。搭建了基于圆结构光的测量系统,分析了系统误差的产生机理并提出了一种基于圆结构光系统测量圆度的方法,可对系统误差进行一定补偿:首先,获取待测深孔的内表面高分辨率三维点云,拟合点云轴线,通过刚体变换将三维点云变换到深孔轴线与相机光轴平行的位置;然后,选定一个测量截面,搜索该截面上的点和与该截面范围较近的点作为圆度评定点;最后,采用网格搜索算法完成圆度评定。测量实验的结果表明,该方法对于圆度误差的补偿效果良好,其中测量不确定度为4.78μm。

压差式流量计误差自动化修正算法研究

针对在多干扰源扰动下压差式流量计测量结果面临输出不稳、误差较大的问题,提出多源扰动下的压差式流量计误差自动化修正算法。考虑全补偿气体可膨胀性系数、压缩系数、密度系数和流出系数等因素,研究压差式流量计误差自动化修正算法。利用均值滤波滤除信号中的高斯噪声,结合一阶滞后滤波优化卡尔曼滤波算法,修正多源扰动误差。引入自组织算法和Volterra神经网络进一步改进卡尔曼滤波算法,并优化卡尔曼滤波算法的先验模型参数,以实现多源扰动误差的自动化修正。试验结果表明,经该算法控制后:当参考流量为900 m^(3)/h时,示值误差绝对值为0.203%;当参考流量为700 m^(3)/h时,流量计重复性为0.06%。该研究可以有效识别并修正由于多源扰动造成的流量异常值,且流量测量精度较高。

基于NSGA-Ⅱ传感位置优化的曲面重构及误差补偿方法

通过优化光纤布拉格光栅形状传感技术中传感点位置和补偿重构结果来提高薄层合金板三维形状重构精度。通过ANSYS workbench建立合金板仿真模型,提取应变和位移模态振型,根据模态置信准则、转换矩阵稳定性和模态振型相似性分别设计了三个目标函数,采用快速和精英机制的多目标遗传算法优化传感器位置。将镍钛合金板弯曲成不同曲率半径的弧形,利用光纤布拉格光栅中心波长漂移量和线性插值算法计算得出不同形状下的结构应变,重构合金板形状,均方根误差和最大误差相较于单目标优化算法分别减小30%和15%。利用粒子群优化径向基函数神经网络算法拟合误差与位移的关系实现误差补偿,均方根误差和最大误差比无补偿时分别减小了90%和70%,最大相对百分比误差仅为5%,提高了三维形状重构算法精度。

狭长空间内重载调姿装配机器人的设计与研究

针对舱体类狭长空间内部待安装设备种类多、批量大、载荷重、空间余量微小、装配路径复杂、装配风险高等问题,设计了一种重载调姿装配机器人。在机器人运动学研究的基础上,建立了误差模型,并以最小包围球半径为约束条件,通过遗传算法将误差参数的辨识结果补偿到机器人控制系统。以机柜装配为例,针对空间约束条件规划工作路径,基于动力学约束能耗函数模型,以时间、冲击和能耗为优化目标,得到多目标最优轨迹。样机实验验证了误差参数辨识的有效性,减小了机器人的绝对定位误差,且多目标最优轨迹的关节总冲击小、运动平稳,实现了机柜类设备高效、平稳、可靠的安装。

高铁5G移动通信系统Multi-TRP上行信道估计及性能研究

Multi-TRP是5G NR的R16增强高速移动场景下的关键技术,在高速铁路中,其信道估计和检测面临更大的挑战。本文对列车高速移动场景下应用Multi-TRP的上行信道估计及性能进行深入研究。考虑到终端到多个TRP的时延和多普勒频偏不同,提出信道估计的时延补偿和多普勒补偿方法。首先,对不同TRP的接收信号分别进行时延和多普勒频偏的补偿;其次,对解调后的信号进行时频域信道估计;最后,采用信道估计矩阵对解调后的信号进行符号检测,以恢复发射信号。同时,从时频域信道估计性能和系统性能2个方面对Multi-TRP系统的上行信道进行性能评估。仿真结果表明,本文所采用的方法显著地改善了信道估计的精度、系统误码性能和频谱效率。

基于小波包算法的斜齿轮滚齿加工误差补偿

斜齿轮滚齿加工依靠2组电子齿轮箱对多轴同步控制,同步误差来源于滚刀B轴的旋转运动和工件C轴的联动误差以及滚刀沿Z轴的轴向运动和工件C轴的联动误差的线性叠加。复杂的运动关系和不平稳的加工状况,使得传统的斜齿轮加工误差补偿困难。采集C轴同步误差信号,利用小波包算法对其进行分解,研究不同频段尺度内子频带信号的幅值分布规律,进行误差特征辨识,重构斜齿轮加工同步误差。根据误差叠加原理,将重构后的同步误差解耦到参与联动的各伺服轴,修改NC代码,将误差量反向补偿到伺服轴。最后通过秦川YK3126数控滚齿机斜齿轮加工误差补偿实例,验证了补偿方法的有效性,提高了斜齿轮的加工精度。

移动互联技术在多船舶通信目标定位中的应用

船舶通信目标定位为船舶导航、避障等提供技术支持,为保障船舶通信目标定位较为准确,研究移动互联技术在多船舶通信目标定位中的应用方法。该方法利用基于移动互联技术的相邻船舶通信节点距离计算方法,获得船舶通信节点距离后,通过计算船舶通信节点距离与距离误差之间关系,并对其求导后得到距离误差补偿量,对多船舶通信节点距离误差实施补偿。以补偿结果为基础,使用基于单移动信标的多船舶通信目标定位方法实现多船舶通信目标定位。实验结果表明,该方法可有效计算船舶通信节点距离并对其误差进行有效补偿,并在不同多船舶环境情况下有效对通信目标进行定位,具备较好的应用效果。

基于多体动力学建模的激光雷达误差研究

激光雷达系统扫描误差主要来源于装配误差和几何误差。由于单方面误差的累加,导致激光雷达系统扫描误差增大,使点云重建的精度降低。针对这一问题,将激光雷达系统扫描中的两种误差源整合到同一坐标系下,建立多体动力学模型,通过对数学模型的解析,完成激光雷达系统扫描误差的分析。

数控机床关键几何误差元素溯源研究

基于螺旋理论对多轴数控机床空间误差建模,利用“十二线法”进行机床几何误差元素辨识实验,获得卧式加工中心的21项几何误差元素值。采用灵敏度分析法对卧式加工中心空间误差模型具有显著影响的关键几何误差元素进行了分析,其中,局部灵敏度分析法溯源出机床11项关键几何误差元素,全局灵敏度分析法溯源出12项几何误差元素。两种溯源方法得到的机床关键几何误差元素不同,但机床关键几何误差元素主要为集中在各运动轴上的线性误差,且各运动轴的转角误差的灵敏度系数均较小,验证了两种溯源方法的适用性。