Geometric Error Identification of Gantry-Type CNC Machine Tool Based on Multi-Station Synchronization Laser Tracers

Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.

Numerical Investigation of Thermal Behavior of CNC Machine Tool and Its Effects on Dimensional Accuracy of Machined Parts

The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.

High Accurate Interpolation of NURBS Tool Path for CNC Machine Tools

Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level without sacrificing the computing efficiency at present. In order to solve this problem, a high accurate interpolation method for NURBS tool path is proposed. The proposed method can efficiently reduce the feedrate fluctuation by forming a quartic equation with respect to the curve parameter increment, which can be efficiently solved by analytic methods in real-time. Theoretically, the proposed method can totally eliminate the feedrate fluctuation for any 2nd degree NURBS curves and can interpolate 3rd degree NURBS curves with minimal feedrate fluctuation. Moreover, a smooth feedrate planning algorithm is also proposed to generate smooth tool motion with considering multiple constraints and scheduling errors by an efficient planning strategy. Experiments are conducted to verify the feasibility and applicability of the proposed method. This research presents a novel NURBS interpolation method with not only high accuracy but also satisfying computing efficiency.

Thermal Error Modeling Method with the Jamming of Temperature-Sensitive Points'Volatility on CNC Machine Tools

Aiming at the deficiency of the robustness of thermal error compensation models of CNC machine tools, the mechanism of improving the models＇ robustness is studied by regarding the Leaderway-V450 machining center as the object. Through the analysis of actual spindle air cutting experimental data on Leaderway-V450 machine, it is found that the temperature-sensitive points used for modeling is volatility, and this volatility directly leads to large changes on the collinear degree among modeling independent variables. Thus, the forecasting accuracy of multivariate regression model is severely affected, and the forecasting robustness becomes poor too. To overcome this effect, a modeling method of establishing thermal error models by using single temperature variable under the jamming of temperature-sensitive points＇ volatility is put forward. According to the actual data of thermal error measured in different seasons, it is proved that the single temperature variable model can reduce the loss of fore- casting accuracy resulted from the volatility of tempera- ture-sensitive points, especially for the prediction of cross quarter data, the improvement of forecasting accuracy is about 5 μm or more. The purpose that improving the robustness of the thermal error models is realized, which can provide a reference for selecting the modelingindependent variable in the application of thermal error compensation of CNC machine tools.

IMPROVING ACCURACY OF CNC MACHINE TOOLS THROUGH COMPENSATION FOR THERMAL ERRORS

A method for improving accuracy of CNC machine tools through compensation for the thermal errors is studied. The thermal errors are obtained by 1 D ball array and characterized by an auto regressive model based on spindle rotation speed. By revising the workpiece NC machining program, the thermal errors can be compensated before machining. The experiments on a vertical machining center show that the effectiveness of compensation is good.

The Research on Hybrid Intelligent Fault-diagnosisSystem of CNC Machine Tools

After analyzing the structure and characteristics of the hybrid intelligent diagnosis system of CNC machine toolsCNC-HIDS), we describe the intelligent hybrid mechanism of the CNC-HIDS, and present the evaluation and the running instance of the system. Through tryout and validation, we attain satisfactory results.

Actualities and Development of Heavy-Duty CNC Machine Tool Thermal Error Monitoring Technology

Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC （computer numerical control） machine tools. Currently, there are many review literatures intro- ducing the thermal error research of CNC machine tools, but those mainly focus on the thermal issues in small and medium-sized CNC machine tools and seldom introduce thermal error monitoring technologies. This paper gives an overview of the research on the thermal error of CNC machine tools and emphasizes the study of thermal error of the heavy-duty CNC machine tool in three areas. These areas are the causes of thermal error of heavy-duty CNC machine tool and the issues with the temperature moni- toring technology and thermal deformation monitoring technology. A new optical measurement technology called the ＂fiber Bragg grating （FBG） distributed sensing tech- nology＂ for heavy-duty CNC machine tools is introduced in detail. This technology forms an intelligent sensing and monitoring system for heavy-duty CNC machine tools. This paper fills in the blank of this kind of review articlesto guide the development of this industry field and opens up new areas of research on the heavy-duty CNC machine tool thermal error.

CPS Modeling of CNC Machine Tool Work Processes Using an Instruction-Domain Based Approach

Building cyber-physical system(CPS) models of machine tools is a key technology for intelligent manufacturing. The massive electronic data from a computer numerical control(CNC) system during the work processes of a CNC machine tool is the main source of the big data on which a CPS model is established. In this work-process model, a method based on instruction domain is applied to analyze the electronic big data, and a quantitative description of the numerical control(NC) processes is built according to the G code of the processes. Utilizing the instruction domain, a work-process CPS model is established on the basis of the accurate, real-time mapping of the manufacturing tasks, resources, and status of the CNC machine tool. Using such models, case studies are conducted on intelligent-machining applications, such as the optimization of NC processing parameters and the health assurance of CNC machine tools.

Reliability Analysis of Electrical System of CNC Machine Tool Based on Dynamic Fault Tree Analysis Method

The electrical system of CNC machine tool is very complex which involves many uncertain factors and dynamic stochastic characteristics when failure occurs.Therefore,the traditional system reliability analysis method,fault tree analysis(FTA)method,based on static logic and static failure mechanism is no longer applicable for dynamic systems reliability analysis.Dynamic fault tree(DFT)analysis method can solve this problem effectively.In this method,DFT first should be pretreated to get a simplified fault tree(FT);then the FT was modularized to get the independent static subtrees and dynamic subtrees.Binary decision diagram(BDD)analysis method was used to analyze static subtrees,while an approximation algorithm was used to deal with dynamic subtrees.When the scale of each subtree is smaller than the system scale,the analysis efficiency can be improved significantly.At last,the usefulness of this DFT analysis method was proved by applying it to analyzing the reliability of electrical system.

An Open CAM System for Dentistry on the Basis of China-made 5-axis Simultaneous Contouring CNC Machine Tool and Industrial CAM Software

China-made 5-axis simultaneous contouring CNC machine tool and domestically developed industrial computer-aided manufacture （CAM） technology were used for full crown fabrication and measurement of crown accuracy, with an attempt to establish an open CAM system for dental processing and to promote the introduction of domestic dental computer-aided design （CAD）/CAM system. Commercially available scanning equipment was used to make a basic digital tooth model after preparation of crown, and CAD software that comes with the scanning device was employed to design the crown by using domestic industrial CAM software to process the crown data in order to generate a solid model for machining purpose, and then China-made 5-axis simultaneous contouring CNC machine tool was used to complete machining of the whole crown and the internal accuracy of the crown internal was measured by using 3D-MicroCT. The results showed that China-made 5-axis simultaneous contouring CNC machine tool in combination with domestic industrial CAM technology can be used for crown making and the crown was well positioned in die. The internal accuracy was successfully measured by using 3D-MicroCT. It is concluded that an open CAM system for den-tistry on the basis of China-made 5-axis simultaneous contouring CNC machine tool and domestic industrial CAM software has been established, and development of the system will promote the introduction of domestically-produced dental CAD/CAM system.

A-B 7300 CNC Machine Tool Rebuilding

This paper describes A-B 7300 CNC machine tool rebuilding, mainly in PAL and AMP utilization of C-type software. It includes PAL program locating and analyzing, AMP capturing etc. After setting PAL and AMP, the greater part of the electrical rebuilding has been accomplished.

A Generic Kinematic Model for Three Main Types of Five-axis Machine Tools

Material removal is one of the most used processes in manufacturing. Five-axis CNC machines are believed to be the best tools in sculptured surface machining. In this study, a generic and unified kinematic model was developed as a viable alternative to the particular solutions that are only applicable to individual machine configurations. This versatile model is then used to verify the feasibility of the two rotational joints within the kinematic chain of three main types of a five-axis machine-tool. This versatile model is very useful applied to the design of five-axis machine tools.

Real-Time Data and Visualization Monitoring of Computer Numerical Control Machine Tools Based on Hyper Text Markup Language 5

In order to ensure the safety,quality and efficiency of computer numerical control(CNC)machine tool processing,a real-time monitoring and visible solution for CNC machine tools based on hyper text markup language(HTML)5 is proposed.The characteristics of the real-time monitoring technology of CNC machine tools under the traditional Client/Server(C/S)structure are compared and analyzed,and the technical drawbacks are proposed.Web real-time communication technology and browser drawing technology are deeply studied.A real-time monitoring and visible system for CNC machine tool data is developed based on Metro platform,combining WebSocket real-time communication technology and Canvas drawing technology.The system architecture is given,and the functions and implementation methods of the system are described in detail.The practical application results show that the WebSocket real-time communication technology can effectively reduce the bandwidth and network delay and save server resources.The numerical control machine data monitoring system can intuitively reflect the machine data,and the visible effect is good.It realizes timely monitoring of equipment alarms and prompts maintenance and management personnel.

Evaluation of Eco-efficiency and Effect on Environment of Remanufacturing A Case Study of CNC-remanufacturing for Used Machining Tools

A case of remanufacturing used lathes via CNC technology is introduced, whose environmental and economic benefits are evaluated respectively. The results indicate that these environmental and economic benefits are remarkable, which are directly affected by remanufacturing design, more than 90% materials in used lathes are reused. Finally, the causes of economic and environmental benefits of remanufacturing machine tools are put forward. The remanufacturing design method, implementation procedure, and evaluation method of economic and environmental benefits presented are helpful for other equipment remanufacturing.

Studies of layout of world machine tools industry based on patent analysis

As the foundation of an industrialized country nowadays,machine tools industry is regarded as the engine of industrial development of a country.The developed countries,such as USA,Germany and Japan,have widely deployed the technology of using the patent in order to keep their strength in various fields.This research examins the CNC machine tools industry in the world by using the patent analysis method.It first gives an overview about the world patent application in CNC machine tools industry from 1963 to 2010 and divides the development of the industry into five stages.It also lists the patent application of the world top 20 countries,where the top 5 countries are compared.The patents of the world top 10 companies of machine tools manufacturers are mapped according to the international patent classification(IPC),and the future trends of world machine tools industry are discussed.Finally conclusions and suggestions are presented.

Patterns of CNC Machine Tool Reference Return and Its Trouble Shooting Methods

This paper presents four patterns of reference-return positions for CNC machine tools and analyses some causes of return reference troubles by showing typical examples of trouble shooting.Finally,it introduces several methods of trouble shooting.

CNC机床丝杠热误差实时补偿设计及自动补偿试验

为了降低数控机床丝杠传动系统因热误差引起的定位误差,完成机床工作台各运行阶段的实时补偿。用非接触模式为丝杠非电机连接端安装位移检测器,以电涡流传感器时间监测丝杠端面位置数据,获得丝杠产生的总热误差,通过热补偿得到每段丝杠的热误差程度,确定每段坐标系原点发生的偏移,完成自主补偿机床丝杠热误差的效果。研究结果表明:采用分段补偿方法可以获得比其他热误差补偿模型更优的丝杠全段补偿性能。分别检测丝杠各段发生的热误差再对其实施补偿,可以根据丝杠各部位热误差程度实施补偿。

Dynamic Modeling of the Feed Drive System of a CNC Metal Cutting Machine

Studying the vibrational behavior of feed drive systems is important for enhancing the structural performance of computer numerical control(CNC)machines.The preload on the screw and nut position have a great influence on the vibration characteristics of the feed drive as two very important operational conditions.Rotational acceleration of the screw also affects the performance of the CNC feed drive when machining small parts.This paper investigates the influence of preload and nut position on the vibration characteristics of the feed drive system of a CNC metal cutting machine in order to be able to eliminate an observed resonance occurred at high rotational speeds of the screw,corresponding to high feed rates.Additionally,rational structural parameters of the feed drive system are selected in order to increase the rotational acceleration for improving the performance of the CNC machine.Experiments and analyses showed that by selecting specific parameters of feed drive system and simultaneously applying a certain value of preload,a 97%increase in rotational acceleration and 30%time reduction considering the vibration resistance at high rotational speeds can be achieved.

WEB-BASED VIRTUAL CNC MACHINE MODELING AND OPERATION

A CNC simulation system based on intemet for operation training of manufacturing facility and manufacturing process simulation is proposed. Firstly, the system framework and a rapid modeling method of CNC machine tool are studied under the virtual environment based on PolyTrans and CAD software. Then, a new method is proposed to enhance and expand the interactive ability of virtual reality modeling language（VRML） by attaining communication among VRML, JavaApplet, JavaScript and Html so as to realize the virtual operation for CNC machine tool. Moreover, the algorithm of material removed simulation based on VRML Z-map is presented. The advantages of this algorithm include less memory requirement and much higher computation. Lastly, the CNC milling machine is taken as an illustrative example for the prototype development in order to validate the feasibility of the proposed approach.

基于TL-DBN方法的CNC机床节能策略设计

为了提高数控机床节能性能,设计一种利用迁移学习方法实现数字控制机床(Computer numerical control,CNC)机床的节能控制过程。建立以随机森林(Random forest,RF)实现驱动功能的离散CNC机床能耗调控模型,减小等待阶段所消耗的能量,促进机床决策效率的快速提升。研究结果表明,时间间隔对机床节能状态影响显著,当间隔增加后,机床由9次切换减少至6次切换,时间间隔设定在25 min最优。各机床都可以在等待阶段通过合适策略达到节能的控制过程,采用该节能控制方案为实现生产过程管控提供了理论依据。