Research on the Dynamic Model of Spindle Rotation Induced Error Compensation System of Boring and its Simulation

In this paper we address the dynamics of compensation cutting process from both Laplace s frequency domain and the time domain of the first time, using the two computer aided analyzing softwares: MATLAB and SIMULINK. Theoretical analysis and simulation experiments firstly show that not only the systematical stiffness of workpiece, spindle and tools, but also the regenerated coefficient affects the compensation displacement effect. The results show that the SREC is practicable in reality to decease the spindle induced errors in many engineering applications such as hard boring through simulation and the preliminary experiment results.

Modeling and Compensation Technology for the Comprehensive Errors of Fixture System

Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.

Thermal Error Compensation for Telescopic Spindle of CNC Machine Tool Based on SIEMENS 840D System

In this paper, eddy current sensors and thermocouple sensors were employed to measure the thermal field and thermal deformation of a spindle of a telescopic CNC boring-milling machine tool, respectively. A linear regression method was proposed to establish the thermal error model. Furthermore, two compensation methods were implemented based on the SIEMENS 840D system by using the feed shaft of z direction and telescopic spindle respectively. Experimental results showed that the thermal error could be reduced by 73.79% when using the second compensation method, and the thermal error could be eliminated by using the two compensation methods effectively.

Non-Exchangeable Error Compensation for Strapdown Inertial Navigation System in High Dynamic Environment

Strapdown non-exchangeable error compensation technology in high dynamic environment is one of the key technologies of strapdown inertial navigation system.Mathematical platform is used in strapdown inertial navigation system instead of physical platform in traditional platform inertial navigation system,which improves reliability and reduces cost and volume of system.The maximum error source of attitude matrix solution is the non-exchangeable error of rotation due to the non-exchangeable of finite rotation of rigid bodies.The rotation non-exchangeable error reaches the maximum in coning motion,although it can be reduced by shortening the correction period and increasing the real-time calculation.The equivalent rotation vector method is used to modify the attitude to reduce the coning error in this paper.Simulation experiments show that the equivalent rotation vector method can effectively suppress the non-exchangeable error and improve the accuracy of attitude calculation.

Machining Complex Oriented Compensation System for Generalized Kinematic Errors

This paper puts forward a machining complex oriented compensation strategy for the generalized kinematic errors (GKEs). According to this strategy, the error map, which is constructed by using the off line measuring information of the machined workpiece, is not oriented for the machine tool but for the machining complex to compensate the GKEs. The error map is derived by the proposed predictive learning control algorithm (PLCA), which is supported by the information model of machining complex. Experimental results show that the machining complex oriented GKEs compensation strategy and the information model based PLCA is effective.

A New Method of Error Compensation for Numerical Control System

This paper presents a method of rapid machine tool error modeling, separation, and compensation using grating ruler. A robust modeling procedure for geometric errors is developed and a fast data processing algorithm is designed by using the error separation technique. After compensation with the new method, the maximum position error of the experiment workbench can be reduced from 400 μm to 15 μm. The experimental results show the effectiveness and accuracy of this method.

Adaptive compensation of sculptured surface machining errors by open architecture manufacturing system

Presents the adaptive compensation of sculptured surface machining errors by using the open architecture intelligent manufacturing system to ensure real time high precision machining of sculptured surface, and the tool deflection model constructed for prediction of machining errors to be compensated and analysis of the effect of tool deflection on machining errors, and concludes from experimental results that the open architecture intelligent manufacturing system can effectively improve the machining precision and reduce the machining errors by 30%.

Research on dynamic error compensation for an armored K type thermocouple

A new method was proposed, in which a high-power CO2 laser modulated by high frequency was used as the driv- ing source to heat up a surface-temperature sensor. The continual beam and the pulsed beam sent out by the same laser could be used in the same system to carry on the static calibration of the radiation thermometer and the dynamic calibration of the temperature sensor to be checked. The frequency-response characteristics of high-speed radiation thermometer surpassed that of the temperature sensor, therefore it could be used as the reference value to calibrate the latter and let system error be cor- rected. Differences in the environment of the sensor installing and the error caused by the change of thermo-physical proper- ty could be avoided. Thus, the difficult problem of traceable dynamic calibration of temperature was solved. In experiment, to obtain the frequency characteristics of the thermocouple and the dynamic performance of the K type thermocouple, which could compensate the dynamic characteristics of the sensor, the sensor was dynamically corrected by using the method, and then the mathematical model was established.

Event-triggered predefined-time control for full-state constrained nonlinear systems: A novel command filtering error compensation method

In this paper, a command filter-based adaptive fuzzy predefined-time event-triggered tracking control problem is investigated for uncertain nonlinear systems with time-varying full-state constraints. By designing a sliding mode differentiator, the inherent computational complexity problem within the predefined-time backstepping framework is solved. Different from the existing command filter-based finite-time and fixed-time control strategies that the convergence time of the filtering error is adjusted through the system initial value or numerous parameters, a novel command filtering error compensation method is presented,which tunes one control parameter to make the filtering error converge in the predefined time, thereby reducing the complexity of design and analysis of processing the filtering error. Then, an improved event-triggered mechanism(ETM) that builds upon the switching threshold strategy, in which an inverse cotangent function is designed to replace the residual term of the ETM,is proposed to gradually release the controller's dependence on the residual term with increasing time. Furthermore, a tan-type nonlinear mapping technique is applied to tackle the time-varying full-state constraints problem. By the predefined-time stability theory, all signals in the uncertain nonlinear systems exhibit predefined-time stability. Finally, the feasibility of the proposed algorithm is substantiated through two simulation results.

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.

Error Compensation of Thin Plate-shape Part with Prebending Method in Face Milling

Low weight and good toughness thin plate parts are widely used in modem industry, but its flexibility seriously impacts the machinability. Plenty of studies locus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surfacc errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling fbrces calculated by the micro-unit cutting force model arc loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed mcthod not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.

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.

Kinematic Calibration and Forecast Error Compensation of a 2-DOF Planar Parallel Manipulator

Due to large workspace,heavy-duty and over-constrained mechanism,a small deformation is caused and the precision of the 2-DOF planar parallel manipulator is affected.The kinematic calibration cannot compensate the end-effector errors caused by the small deformation.This paper presents a method combined step kinematic calibration and linear forecast real-time error compensation in order to enhance the precision of a two degree-of-freedom(DOF) planar parallel manipulator of a hybrid machine tool.In the step kinematic calibration phase of the method,the end-effector errors caused by the errors of major constant geometrical parameters is compensated.The step kinematic calibration is based on the minimal linear combinations(MLCs) of the error parameters.All simple and feasible measurements in practice are given,and identification analysis of the set of the MLCs for each measurement is carried out.According to identification analysis results,both measurement costs and observability are considered,and a step calibration including step measurement,step identification and step error compensation is determined.The linear forecast real-time error compensation is used to compensate the end-effector errors caused by other parameters after the step kinematic calibration.Taking the advantages of the step kinematic calibration and the linear forecast real-time error compensation,a method for improving the precision of the 2-DOF planar parallel manipulator is developed.Experiment results show that the proposed method is robust and effective,so that the position errors are kept to the same order of the measurement noise.The presented method is attractive for the 2-DOF planar parallel manipulator and can be also applied to other parallel manipulators with fewer than six DOFs.

Modeling Approach of Regression Orthogonal Experiment Design for Thermal Error Compensation of CNC Turning Center

The thermal induced errors can account for as much as 70% of the dimensional errors on a workpiece. Accurate modeling of errors is an essential part of error compensation. Base on analyzing the existing approaches of the thermal error modeling for machine tools, a new approach of regression orthogonal design is proposed, which combines the statistic theory with machine structures, surrounding condition, engineering judgements, and experience in modeling. A whole computation and analysis procedure is given. Therefore, the model got from this method are more robust and practical than those got from the present method that depends on the modeling data completely. At last more than 100 applications of CNC turning center with only one thermal error model are given. The cutting diameter variation reduces from more than 35 μm to about 12 μm with the orthogonal regression modeling and compensation of thermal error.

A convenient look-up-table based method for the compensation of non-linear error in digital fringe projection

Although the structured light system that uses digital fringe projection has been widely implemented in three-dimensional surface profile measurement, the measurement system is susceptible to non-linear error. In this work, we propose a convenient look-up-table-based （LUT-based） method to compensate for the non-linear error in captured fringe patterns. Without extra calibration, this LUT-based method completely utilizes the captured fringe pattern by recording the full-field differences. Then, a phase compensation map is established to revise the measured phase. Experimental results demonstrate that this method works effectively.

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.

Thermal Error Compensation of the Wear-Depth Real-Time Detecting of Self-Lubricating Spherical Plain Bearings

The spherical plain bearing test bench is a necessary detecting equipment in the research process of self?lubricating spherical plain bearings. The varying environmental temperatures cause the thermal deformation of the wear?depth detecting system of bearing test benches and then a ect the accuracy of the wear?depth detecting data. However, few researches about the spherical plain bearing test benches can be found with the implementation of the detect?ing error compensation. Based on the self?made modular spherical plain bearing test bench, two main causes of ther?mal errors, the friction heat of bearings and the environmental temperature variation, are analysed. The thermal errors caused by the friction heat of bearings are calculated, and the thermal deformation of the wear?depth detecting sys?tem caused by the varying environmental temperatures is detected. In view of the above results, the environmental temperature variation is the main cause of the two error factors. When the environmental temperatures rise is 10.3 °C, the thermal deformation is approximately 0.01 mm. In addition, the comprehensive compensating model of the thermal error of the wear?depth detecting system is built by multiple linear regression(MLR) and time series analysis. Compared with the detecting data of the thermal errors, the comprehensive compensating model has higher fitting precision, and the maximum residual is only 1 μm. A comprehensive compensating model of the thermal error of the wear?depth detecting system is proposed, which provides a theoretical basis for the improvement of the real?time wear?depth detecting precision of the spherical plain bearing test bench.

Technical Research for Detector of Grain Moisture Content Based on Error Compensation

According to the existing method including testing the frequency and establishing the relationship between moisture content and frequency, a corresponding instrument was designed. In order to further improve the accuracy and rapidity of the system, a new approach to describe the relationship between the measurement error and the temperature was proposed. The error band could be obtained and divided into several parts（based on the range of temperature） to indicate the error value that should compensate the grain moisture content for the changes in temperature. By calculating the error band at the maximum and the minimum operating temperatures, as well as by determining the error compensation value from the error band based on the measurement moisture content, the final effective result was derived.

ERROR COMPENSATION OF COORDINATE MEASURING MACHINES WITH LOW STIFFNESS

A technique for compensating the errors of coordinate measuring machines (CMMs) with low stiffness is proposed. Some additional items related with the force deformation are introduced to the error compensation aquations. The research was carried on a moving colunm horizontal arm CMM. Experimental results show that both the effects of systematic components of error motions and force deformations are greatly reduced, which shows the effectiveness of proposed technique.

The Error Compensation of Inclinometer Based on Polynomial Fitting

In order to reduce the influence of nonlinear characteristic and temperature on the measuring accuracy of inclinometer, the application of polynomial fitting principle to compensate the measuring error of inclinometer is studied. According to the analysis of the experimental data of inclinometer, a polynomial model of the nonlinear error and the measured value is constructed, and then the relation between the coefficient of the polynomial model and the temperature is obtained by fitting, and finally the function of the measurement error of inclinometer on the measured inclination and temperature is obtained. The results show that this method is feasible and effective, which can not only reduce the influence of temperature, but also correct its nonlinear error.