Five-axis horizontal machining center swing head test bench and detection method thereof

Abstract

The invention provides a five-axis horizontal machining center swing head test bench and a detection method thereof. The five-axis horizontal machining center swing head test bench comprises a base, a stand column and a swing head. The base is vertically and fixedly connected with a stand column, the stand column is provided with a to-be-measured swing head through a positioning transition module, and the to-be-measured swing head comprises a to-be-measured spindle axis S and a to-be-measured rotating shaft axis A; the to-be-detected swing head is provided with a plurality of interference type sensors, the interference type sensors are connected with the industrial personal computer, and the industrial personal computer is used for conducting closed-loop tracing detection on the to-be-detected module. According to the invention, high-precision automatic traceability detection of the swinging head of the five-axis horizontal machining center is realized, and the detection efficiency is effectively improved.

Description

Technical Field

[0001] The invention belongs to the technical field of static or dynamic balance testing of machines or structural components, and in particular relates to a five-axis horizontal machining center swing head testing bench and a testing method thereof. Background Art

[0002] In recent years, domestic five-axis horizontal machining centers have developed rapidly, especially in the military and civilian industries such as aerospace, navigation, gas turbines, and compressors, where demand continues to grow. At present, the process and function detection of the five-axis swing head mostly rely on manual labor, which has the problems of low efficiency and difficulty in error tracing. Therefore, the present invention aims to design a process measurement test bench to meet the requirements of precision detection and function verification of the swing head. In this regard, the following technical solution is proposed. Summary of the invention

[0003] The technical problem solved by the present invention is to provide a five-axis horizontal machining center swing head test bench and a detection method thereof, so as to realize high-precision automatic traceability detection of the five-axis horizontal machining center swing head.

[0004] The technical solution adopted by the present invention is: a five-axis horizontal machining center swing head test bench, including a base, a column, and a swing head; the base is vertically fixed to the column, and the column is installed with a swing head to be tested through a positioning transition module, and the swing head to be tested includes a spindle axis S to be tested and a rotating shaft axis A to be tested; the swing head to be tested is installed with a plurality of interference sensors, and the interference sensors are connected to an industrial computer, and the industrial computer is used to perform closed-loop traceability detection on the module to be tested.

[0005] Furthermore: the positioning transition module includes a connecting piece, a positioning pin, and an adjusting bolt.

[0006] Furthermore: it also includes an adjustable washer, which is arranged at the bottom of the base 1.

[0007] Furthermore, the industrial computer 5 includes a display 51 and a key control area 52 .

[0008] Furthermore: the industrial computer 5 includes a square box module 6.

[0009] Furthermore: the square box module 6 is externally arranged on the horizontal surface of the base 1 , or the direction module 6 is integrated with the industrial computer 5 .

[0010] Furthermore: the industrial computer 5 also includes an electrical system; the electrical system at least includes a power supply module, a power distribution module, a control module, a programming module, and a protection module.

[0011] The present invention also claims protection for a detection method of a five-axis horizontal machining center swing head test bench, the test bench being any of the aforementioned test benches, and the column 2 of the test bench is installed with the swing head 3 to be tested through the positioning transition module 4 to complete the following detection contents:

[0012] S1, perpendicularity measurement of the rotating shaft axis A and the main shaft axis S;

[0013] S2, measurement of the deviation between the rotating shaft axis A and the main shaft axis S;

[0014] S3, detection of the runout of the rotating shaft axis A;

[0015] The above detection steps are carried out simultaneously or sequentially, wherein the TCP accuracy is ±0.02 and shall not be lower than this accuracy;

[0016] The test bench calculates the geometric error by weighted average method.

[0017] The advantages of the present invention compared with the prior art are:

[0018] 1. The test bench of the present invention realizes high-precision measurement, real-time compensation and intelligent diagnosis of head swing errors through closed-loop collaboration between interference sensors and industrial computers, significantly improving the performance verification efficiency and reliability of the five-axis horizontal machining center, and providing key technical guarantees for high-end equipment manufacturing.

[0019] 2. The setting of the positioning transition module of the present invention can achieve high-precision positioning, has good rigidity and stability, is easy to install and adjust, has certain versatility and scalability, and effectively improves test efficiency.

[0020] 3. The present invention arranges an adjustable shim at the bottom of the base, which can systematically improve the test accuracy and reliability of the test bench through precise leveling, enhanced stability, adaptation to complex environments and simplified maintenance. It is a key technical design in the swing head test of the five-axis horizontal machining center.

[0021] 4. The integrated display and key control area of the industrial computer of the present invention significantly improves the usability, reliability and intelligence level of the five-axis horizontal machining center swing head test bench through real-time visualization, efficient interaction, safe control and collaborative expansion capabilities, and is the core technical support for the precision detection of high-end equipment.

[0022] 5. The industrial computer integrated box module of the present invention systematically solves the core problems such as benchmark drift, environmental interference, data distortion, etc. in the swing head test of the five-axis horizontal machining center through high-precision benchmark, environmental isolation, signal optimization and modular design, improves the test accuracy by an order of magnitude, and shortens the preparation time by more than 50%. It is a key technical module for precision detection of high-end equipment.

[0023] 6. The electrical system of the industrial control computer of the present invention collaborates through five major modules: power supply, power distribution, control, programming, and protection, systematically solving the core problems such as power supply stability, control real-time performance, programming flexibility, and safety protection in the swing head test of a five-axis horizontal machining center; it has high stability (power supply fluctuation <0.1%), high real-time performance (control delay <1 μs), high flexibility (open programming architecture), and low failure rate (MTBF 50,000 h). Users can rely on this electrical system to achieve a 30% improvement in swing head test accuracy, a 50% improvement in test efficiency, and significantly reduce the difficulty of equipment operation and maintenance.

[0024] 7. The measurement method of the test bench of the present invention realizes high-precision measurement and evaluation; comprehensively evaluating this method can fully reflect the geometric accuracy status of the machine tool, providing strong support for the performance evaluation and quality control of the machine tool; the flexibility of weight allocation makes the geometric error evaluation more in line with the actual machining requirements, improving the pertinence and effectiveness from component assembly to whole machine assembly; through accurate geometric error evaluation, the accuracy status of the machine tool can be understood, thereby optimizing the whole machine assembly work, improving the whole machine assembly efficiency and reducing the rework rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is the front view of the present invention;

[0026] Figure 2 is the side view of the present invention;

[0027] Figure 3 is the connection block diagram of the electrical system of the present invention;

[0028] Figure 4 is the electrical schematic diagram of the A-axis drive and brake of the present invention;

[0029] Figure 5 is the bus topology diagram related to the present invention;

[0030] Figure 6 is the power supply diagram related to the present invention;

[0031] In the figure: 1 - base, 2 - column, 3 - swing head to be tested, 31 - spindle axis S, 32 - rotation axis A, 4 - positioning transition module, 5 - industrial control computer, 51 - display, 52 - key control area, 6 - square box module. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the attached Figure 1-6 drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0033] Example 1: A five-axis horizontal machining center swivel head test bench, comprising a base 1, a column 2, and a swivel head 3; the base 1 is vertically and fixedly connected to the column 2, and the column 2 installs the swivel head 3 to be tested through a positioning transition module 4. The swivel head 3 to be tested includes a spindle axis S to be tested and a rotation axis A to be tested; several interference sensors are installed on the swivel head 3 to be tested, and the interference sensors are connected to an industrial control computer 5, and the industrial control computer 5 is used for closed-loop traceability detection of the module to be tested.

[0034] Regarding Example 1, it should be noted that:

[0035] Using laser interferometry, the resolution can reach the nanometer level (such as 0.1 nm), far exceeding traditional detection methods, and can accurately capture the minute displacement and angular deviation of the swivel head.

[0036] Multiple sensors are arranged at key parts of the swivel head (such as the spindle and the rotation axis) to work together to achieve synchronous monitoring of multi-degree-of-freedom errors and ensure no dead angle in detection.

[0037] Closed-loop control mechanism: The industrial control computer 5 analyzes the sensor data in real time, identifies the error sources (such as geometric errors and thermal deformations) through an algorithm model, and automatically adjusts the motion parameters of the swivel head to compensate for the errors. During the high-speed rotation or complex trajectory movement of the swivel head, the closed-loop system can correct the trajectory deviation in real time, improving the machining accuracy and stability.

[0038] The industrial control computer 5 decomposes the comprehensive error into components such as geometric error, thermal error, and dynamic error, accurately locates the root cause of the error. Through long-term data accumulation, an error trend model is established to predict the deterioration of the swivel head performance in advance and reduce the risk of downtime.

[0039] The industrial control computer 5 integrates a high-speed data processing module, supports real-time analysis of a large amount of sensor data, generates visual results such as error distribution cloud maps and spectrograms, provides an intuitive graphical interface, and operators can quickly understand the error status and formulate targeted maintenance strategies.

[0040] The positioning transition module 4 supports quick replacement of different models of swivel heads to meet the test requirements of multiple varieties. The industrial control computer 5 can support new sensors or algorithms through firmware updates, extending the equipment life cycle.

[0041] The comparison between the present invention and the traditional manual detection method is shown in Table 1 below:

[0042] Technical indicators Traditional detection method Closed-loop traceability detection Measurement accuracy Micron level (1-5μm) Nanometer level (0.1nm) Real-time performance Postmortem analysis Real-time feedback and adjustment Error diagnosis ability Rely on manual experience Automatically decompose and locate error sources Data processing efficiency Inefficient and rely on manual processing High-efficiency automated analysis Adaptability Fixed process, poor flexibility Modular design, support multiple scenarios

[0043] It can be seen that through the closed-loop collaboration between the interference sensor and the industrial control computer 5, the test bench of the present invention realizes high-precision measurement, real-time compensation, and intelligent diagnosis of the swing error, significantly improves the performance verification efficiency and reliability of the five-axis horizontal machining center, and provides key technical support for high-end equipment manufacturing.

[0044] Embodiment 2: Further, the positioning transition module 4 includes a connecting piece, a positioning pin, and an adjusting bolt.

[0045] Regarding Embodiment 2, it should be noted that:

[0046] The positioning transition module 4 is used to connect the column 2 and the swing head 3 to be measured, ensuring that the swing head 3 to be measured can be accurately and stably installed on the test bench and high-precision testing can be carried out. Its specific composition includes but is not limited to components such as high-precision connecting pieces, positioning pins, adjusting bolts, etc., as well as a strengthening structure for ensuring connection rigidity and stability.

[0047] The positioning transition module 4 adopts precise design and manufacturing processes, which can ensure that when the swing head 3 to be measured is installed on the column 2, its position and direction are precisely controlled. This helps to reduce test errors caused by installation errors and improve the accuracy and reliability of the test.

[0048] The positioning transition module 4 is usually made of high-strength materials and is designed with a strengthening structure to ensure that it can withstand the weight and dynamic load of the swing head 3 to be measured during the test while maintaining a stable connection state. This helps to reduce test errors caused by vibration and deformation and improve the stability of the test.

[0049] The positioning transition module 4 is usually designed with a structure that is easy to install and adjust, which enables the operator to conveniently install the swing head 3 to be measured on the test bench and make precise adjustments to ensure the accuracy and consistency of the test conditions.

[0050] The positioning transition module 4 has standardized interfaces and dimensions to adapt to different models and specifications of the swing heads 3 to be measured. This enables the test bench to be used for testing swing heads of various types of five-axis horizontal machining centers, improving the versatility and expandability of the test bench.

[0051] By adopting the positioning transition module 4, the installation and adjustment process of the swing head to be measured can be simplified, and the test preparation time can be reduced. At the same time, due to the high precision and stability of the module 4, the accuracy and reliability of the test results can be ensured, thereby improving the test efficiency.

[0052] Embodiment 3: Further, it also includes adjustable shims, and the adjustable shims are arranged at the bottom of the base 1.

[0053] Regarding Embodiment 3, it should be noted that:

[0054] The adjustable shims allow for fine adjustment of the height of the base 1 (usually with an accuracy of up to 0.01 mm), ensuring that the entire test bench is in a horizontal state. By adjusting the height of the shims, uneven ground or installation errors can be compensated for, avoiding geometric errors caused by tilting of the swing head (such as the perpendicularity deviation between the spindle axis S and the rotation axis A).

[0055] The adjustable shims firmly fix the base 1 to the ground through a pre-tightening force, reducing vibration transmission and enhancing the stability of the test bench during high-speed rotation or heavy-load testing. The adjustable structure can optimize the contact stiffness between the base and the ground, reducing interference from external vibrations on the measurement accuracy of the interferometric sensor.

[0056] When there are local depressions or protrusions on the factory floor, the shims can achieve the flatness of the base 1 through multi-point adjustment, avoiding equipment deformation caused by local stress concentration. The test bench can quickly adapt to different installation sites (such as temporary test points or different workshops) without the need for customized foundations, reducing deployment costs.

[0057] After equipment relocation or long-term use, the horizontal level of the test bench can be restored by adjusting the shims without disassembling the structural components. The shims can absorb minor settlement of the foundation, reducing long-term accuracy drift caused by foundation deformation and extending the equipment calibration cycle.

[0058] The horizontal level adjustment can ensure that the rotation center of the swing head coincides with the column axis, avoiding eccentric errors introduced by tilting. The stable base support can reduce random vibration noise, improving the repeatability and reliability of the measurement data of the interferometric sensor.

[0059] Example illustration: Suppose the test bench needs to test the dynamic accuracy of the swing head 3 at high speed rotation (such as 20,000 rpm). If the base 1 has an inclination of 0.1°, it may cause a radial deviation of approximately 0.017 mm of the spindle axis S (calculated based on a 500 mm overhang length). By adjusting the inclination angle to less than 0.01° through the adjustable shims, this deviation can be reduced to within 0.0017 mm, significantly improving the test accuracy.

[0060] Embodiment 4: Further, the industrial control computer 5 includes a display 51 and a key control area 52.

[0061] Regarding Embodiment 4, it should be noted that:

[0062] The display 51 can display the measurement data of the interferometric sensor (such as displacement, angle deviation) in real time, and present the movement trajectory of the swing head in the form of charts (such as line charts, spectrograms) or 3D models, helping the operator intuitively judge the equipment status. The error distribution of each part of the swing head is displayed through color mapping to quickly locate high-error areas (such as the spindle end or the rotation axis connection).

[0063] The display 5 supports the simultaneous display of multi-source data such as spindle speed, temperature, vibration, etc., facilitating correlation analysis (such as the impact of thermal deformation on geometric error). Historical test records can be retrieved to compare the error trends at different time points, assisting in fault tracing.

[0064] When the display 51 has a touch function, the operator can directly adjust test parameters (such as sampling frequency, filtering threshold) on the screen, reducing the dependence on the keyboard. When the error exceeds the set threshold, a warning box automatically pops up on the screen and highlights the abnormal data, shortening the response time.

[0065] The key control area 52 provides dedicated function keys (such as "Start Test", "Calibration", "Mode Switching"), ensuring basic operations can still be carried out even when the touch screen malfunctions. Preset test procedures (such as "High-speed Rotation Test", "Load Dynamic Test") can be quickly invoked through key combinations, improving operation efficiency.

[0066] The key control area 52 independently sets an emergency stop button to immediately cut off the power supply in case of sudden abnormalities (such as out-of-control head swinging), ensuring the safety of personnel and equipment. Operation permission management is achieved through key combinations (such as the administrator mode can modify core parameters, and ordinary users can only execute tests), preventing misoperations.

[0067] Use a knob or numeric keys to accurately input test parameters (such as target speed, sampling time), avoiding input errors on the touch screen. Trigger data saving through keys to store test results (including raw data, analysis reports) locally or in the cloud, meeting traceability requirements.

[0068] When the display 51 and the key control area 52 work together, the display 51 shows key information, and the key control area 52 provides physical feedback, conforming to the "visual-tactile" collaborative operation habit and reducing the learning cost. The display 51 and the key control area 52 are integrally designed, reducing the movement of the operator between the device and the console and improving work efficiency.

[0069] While observing real-time data on the display 51, input debugging commands (such as single-step execution, variable monitoring) through the key control area 52 to quickly locate software or hardware faults.

[0070] The interfaces of the display 51 and the key control area 52 reserve expansion capabilities (such as USB, HDMI, CAN bus), supporting the access of new sensors or peripherals (such as laser tracker, vibration analyzer). Switch the display language interface through the key control area to adapt to the needs of global deployment.

[0071] The comparison between the present invention and traditional industrial control computers is shown in Table 2 below:

[0072]

[0073] Example 5: Further, the industrial control computer 5 includes a square box module 6.

[0074] Regarding Example 5, it should be noted that: The square box module 6 is a precision mechanical structure, integrated inside the industrial control computer 5 or used as its expansion unit. Its main functions include providing a high-precision reference plane (serving as the mechanical reference for the swing head 3 test to ensure the accuracy of the sensor installation position and measurement direction), isolating environmental interference (reducing the impact of external factors such as temperature and vibration on the measurement accuracy through a closed design), and integrating a signal conditioning circuit (preprocessing the original signals of the interferometric sensors, such as filtering and amplification, to improve the data transmission stability).

[0075] The flatness of the square box module 6 can generally reach 0.005 mm / m, ensuring that the perpendicularity error between the sensor installation surface and the rotation center line of the swing head 3 is <0.01°, avoiding systematic errors introduced due to reference deviations. In multiple clamping tests, the mechanical rigidity of the square box module 6 can maintain the sensor position deviation <0.002 mm, significantly improving the repeatability of the test data.

[0076] The square box module 6 is made of a material with a low coefficient of thermal expansion (such as Invar), and its thermal deformation is <0.001 mm / m within the range of 20°C ± 5°C, reducing the impact of temperature changes on the measurement accuracy. The built-in vibration damping structure (such as rubber damping pads or pneumatic vibration isolators) can attenuate external vibrations by more than 80%, ensuring that the interferometric sensor can still work stably during high-speed rotation tests (such as 20,000 rpm).

[0077] The digital filter integrated in the square box module 6 can filter out high-frequency noise (such as 50 Hz power frequency interference), increasing the signal-to-noise ratio of the signal by 30%. Using shielded cables and differential signal transmission reduces the impact of electromagnetic interference on weak optical signals (such as laser interferometers), and the data transmission error rate is <10^-6.

[0078] The square box module 6 provides standardized interfaces (such as M6 threaded holes, SMA fiber optic connectors), enabling quick replacement of different types of sensors (such as capacitive, inductive) to adapt to different test requirements. By replacing the internal circuit board of the square box module 6, higher sampling rates (such as 10 MHz) or new data processing functions (such as edge computing) can be supported without replacing the entire industrial control computer 5.

[0079] The comparison between the integrated square box module of the present invention and the traditional solution is shown in Table 3 below:

[0080]

[0081] Application scenario example: During high-speed swing dynamic testing, when the swing head 3 rotates at 15,000 rpm, the vibration damping design of the square box module 6 reduces the vibration noise from ±0.1 μm to ±0.02 μm, ensuring that the interferometric sensor accurately captures the radial runout of the spindle (error < 0.003 mm). During multi-physical field coupling testing, the temperature compensation function of the square box module 6 corrects the thermal deformation error from ±0.02 mm to ±0.002 mm under a 30°C temperature difference, significantly improving the accuracy of thermal-mechanical coupling testing.

[0082] Embodiment 6: Further, the square box module 6 is externally disposed on the upper horizontal surface of the base 1, or the direction module 6 is integrated with the industrial control computer 5.

[0083] Regarding Embodiment 6, it should be noted that: The externally placed square box module 6 is directly installed on the base 1, forming an independent mechanical reference, avoiding interference of the internal vibration or temperature change of the industrial control computer 5 to the measurement reference. The large mass structure of the base 1 (such as a cast iron platform) provides higher rigidity, reducing the minute deformation of the square box module during high-speed rotation testing (such as from 0.005 mm to 0.002 mm).

[0084] The external design makes the square box module 6 away from the heat-generating components (such as the CPU) of the industrial control computer 5, reducing the thermal coupling effect, and the thermal deformation is < 0.0005 mm / m within the range of 20°C ± 5°C. The square box module 6 can be connected to the base 1 through an independent shock absorber (such as a rubber pad), further attenuating external vibrations (such as ground low-frequency vibrations), and reducing the vibration transmission rate to less than 10%.

[0085] The externally placed square box module 6 can be disassembled separately without opening the chassis of the industrial control computer 5, shortening the sensor calibration or module replacement time to 5 minutes. The square box module 6 can be connected to multiple sensors simultaneously (such as a laser interferometer, a capacitance micrometer), and transmit data to the industrial control computer 5 at high speed (bandwidth up to 5 Gbps) through an external interface (such as USB-3.0).

[0086] The externally placed square box module 6 can be purchased separately, and users can select different precision levels according to their needs (such as standard type 0.005 mm / m vs high-precision type 0.002 mm / m), reducing the initial investment. Avoiding overcrowding in the internal space of the industrial control computer 5, reducing internal cable interference, and improving the overall reliability of the system.

[0087] When the square box module 6 is integrated with the industrial control computer 5, the signal transmission and real-time performance are improved, and the system is compact and portable.

[0088] Embodiment 7, further: The industrial control computer 5 further includes an electrical system; the electrical system at least includes a power module, a power distribution module, a control module, a programming module, and a protection module.

[0089] Regarding Embodiment 7, it should be noted that: The power supply module converts the commercial power (AC 220V) into stable direct current (such as DC 24V, ±15V, 5V) required by the industrial computer 5 and sensors. A hybrid design of linear voltage regulation + switching power supply is adopted, with voltage fluctuation <0.1% (such as the ±15V output is used for the interferometric sensor) to avoid signal drift. It supports AC 100 - 240V input, adapts to the global grid standard, and reduces equipment restart caused by unstable voltage. Two power supply modules are connected in parallel (such as N + 1 redundancy), and the system can still operate when a single power supply fails, improving reliability.

[0090] The power distribution module distributes power to each component as needed (such as the square box module 6, the display 51, the keypad area 52), and realizes overload / short - circuit protection. Dynamic power distribution is achieved through relays or MOSFETs, giving priority to ensuring power supply for key equipment (such as the interferometer). When a certain load is short - circuited, the power distribution module can cut off the faulty circuit within 10ms to avoid affecting other equipment. The power consumption of each module is recorded in real - time (such as the power consumption of the square box module 6 <50W), providing data support for energy - saving optimization.

[0091] The control module coordinates the work of each hardware unit, such as starting the test process, adjusting the sensor sampling rate, and controlling the motor speed. An FPGA or a real - time operating system (such as RTOS) is adopted, with a control instruction delay <1μs to meet the requirements of high - speed dynamic testing. It supports five - axis synchronous control of XYZAC, with a position synchronization error <0.001°, ensuring the precise movement trajectory of the swing head 3. The PID control algorithm is integrated to adjust the output in real - time according to the sensor feedback (such as compensating for the thermal deformation of the main shaft).

[0092] The programming module provides a user programming interface, supporting custom test processes and data analysis algorithms. Open architecture: Supports high - level languages such as Python / C++, and users can quickly develop test scripts (such as error compensation algorithms). Graphical programming: Provides interfaces for LabVIEW or MATLAB Simulink, reducing the programming threshold for non - professional users. Remote debugging: Remote code upload and debugging are realized through Ethernet or 5G, reducing on - site maintenance time.

[0093] The protection module monitors system anomalies (such as overvoltage, overcurrent, overheating), and triggers protection actions. Multi - level protection: Dual protection at the hardware level (such as TVS diodes for surge protection) + software level (such as over - current threshold setting). Fault recording: Records the protection trigger time, type, and data before the fault (such as voltage curve), facilitating post - event analysis. Automatic recovery: After some faults (such as instantaneous overvoltage) are eliminated, the system can automatically restart, reducing manual intervention.

[0094] The overall power supply module and protection module of the electrical system work together to reduce the impact of mains fluctuations on test accuracy by 90%. Fault tolerance: The power distribution module and redundant power supply design increase the mean time between failures (MTBF) of the system to over 50,000 hours. The real-time performance of the control module ensures seamless connection of the test process, shortening the single test time by 30%. The open architecture of the programming module allows users to customize the automated test process and reduce manual operation errors. The protection module covers more than 10 types of faults such as overvoltage, overcurrent, and overheating to ensure the safety of personnel and equipment. Set the operation permissions through the programming module to prevent misoperations (such as unauthorized personnel modifying key parameters).

[0095] The present invention also claims a detection method for a swivel head test bench of a five-axis horizontal machining center. The test bench is any one of the aforementioned test benches. After installing the swivel head 3 to be measured through the positioning transition module 4 on the column 2 of the test bench, the following detection contents are completed:

[0096] S1. Measuring the perpendicularity between the axis A of the rotating shaft and the axis S of the spindle;

[0097] S2. Measuring the deviation between the axis A of the rotating shaft and the axis S of the spindle;

[0098] S3. Detecting the runout of the axis A of the rotating shaft.

[0099] The above detection steps are carried out simultaneously or sequentially, where the TCP accuracy is ±0.02 and shall not be lower than this accuracy.

[0100] The test bench calculates the geometric error by the weighted average method.

[0101] The detection results are as follows: The angular deviation of the swing head in the YZ plane is 0.025 / 1000; the perpendicularity between the swing head (along Y) and the column (along X) axis is 0.008 / 500; the perpendicularity between the swing head (along Y) and the column (along Z) axis is 0.008 / 500.

[0102] Among them, in order to calculate the geometric error, especially the perpendicularity, deviation between the axis A of the rotating shaft and the axis S of the spindle, and the runout of the axis A of the rotating shaft, the following mathematical calculation methods and measurement principles can be adopted:

[0103] Perpendicularity measurement: Perpendicularity is usually evaluated by measuring the angle between two axes. In the present invention, a laser interferometer can be used to measure the angle between the axis A of the rotating shaft and the axis S of the spindle;

[0104] Let the actual angle between the axis A of the rotating shaft and the axis S of the spindle be θ, and the angle in the ideal perpendicular case be 90°. Then the perpendicularity error Δθ can be expressed as:

[0105] Δθ = ∣90° - θ∣

[0106] This error is usually measured in degrees or radians and can be converted to deviation per unit length, such as mm / m or in / ft, for comparison with a given accuracy standard (e.g., 0.008 / 500).

[0107] Measurement of deviation amount: The deviation amount refers to the offset of the axis A of the rotating shaft relative to its ideal position. This can be measured by selecting multiple points on the axis A of the rotating shaft and using a coordinate measuring machine (CMM) or a laser tracker to measure the actual coordinates of these points; assume that the equation of the axis A of the rotating shaft in the ideal case is Ax + By + Cz + D = 0, and the equation of the axis obtained from the actual measurement is A'x + B'y + C'z + D' = 0. Then the deviation amount can be obtained by calculating the distance between two planes (or lines, usually considering planes or projections onto planes in three-dimensional space); for a line or axis, the deviation amount is usually expressed as the minimum distance or the maximum distance, and specific numerical values can be given, such as the angular deviation of the swivel head in the YZ plane being 0.025 / 1000.

[0108] Measurement of runout amount: The runout amount refers to the maximum offset of the axis of the rotating shaft relative to a fixed reference point during rotation. This is usually measured by a sensor installed on the rotating shaft; assume that during the rotation of the rotating shaft, the maximum offset measured by the sensor is Δd, then the runout amount is Δd. This value is usually compared with a given accuracy standard (e.g., TCP accuracy of ±0.02) to ensure that it does not exceed the allowable range.

[0109] Comprehensive calculation of geometric errors: In practical applications, geometric errors may include a combination of perpendicularity errors, deviation amounts, and runout amounts. To obtain a comprehensive geometric error assessment, these error components can be weighted and summed or the maximum value can be taken as the final geometric error according to specific application requirements and accuracy standards.

[0110] For example, if the perpendicularity error, deviation amount, and runout amount are represented by Δθ, Δdeviation, and Δrunout respectively, and their weights are w θ 、w 偏差 and w 跳动 , then the comprehensive geometric error Δgeometry can be expressed as:

[0111] Δgeometry = w θ Δθ + w 偏差 Δdeviation + w 跳动 Δrunout

[0112] In actual operation, the weights w θ 、w 偏差 and w 跳动 should be determined according to specific measurement requirements and accuracy standards.

[0113] Regarding this measurement method, it should be noted that: for perpendicularity measurement, the angle between the axis A of the rotating shaft and the axis S of the spindle is measured by a laser interferometer, which can accurately evaluate the perpendicularity error between the two axes. This high-precision measurement ensures the geometric accuracy of the machine tool during the machining process, thereby improving the quality of the machined parts. For deviation measurement, the actual coordinates of multiple points on the axis A of the rotating shaft are measured by a laser tracker, and the offset of the axis relative to the ideal position can be accurately calculated. This measurement method can detect the possible small deviations in the manufacturing or assembly process of the machine tool, providing a basis for subsequent debugging and correction. For runout measurement: the maximum offset of the rotating shaft during rotation, that is, the runout, is measured by a sensor (such as a displacement sensor) installed on the rotating shaft. This index directly reflects the rotation accuracy and stability of the rotating shaft, which is crucial for ensuring the surface quality and dimensional accuracy of the machined parts.

[0114] The geometric error components such as perpendicularity error, deviation, and runout are weighted and summed or the maximum value is taken as the final geometric error. This comprehensive evaluation method can comprehensively reflect the geometric accuracy status of the machine tool, providing strong support for the performance evaluation and quality control of the machine tool. According to specific application requirements and accuracy standards, the weights of each error component can be flexibly allocated. This flexibility makes the geometric error evaluation more in line with the actual machining requirements, improving the pertinence and effectiveness of the evaluation.

[0115] Through accurate geometric error evaluation, the accuracy status of the machine tool can be understood, thereby optimizing the machining parameters and improving the machining accuracy and efficiency. For example, when it is found that the runout of the rotating shaft is too large, the assembly or lubrication conditions of the machine tool can be adjusted in time to reduce the runout and improve the machining quality. The accurate evaluation and control of geometric errors help to reduce the scrap rate during the machining process. By timely detecting and correcting the geometric errors of the machine tool, problems such as out-of-tolerance dimensions and poor surface quality of the machined parts caused by insufficient machine tool accuracy can be avoided, thereby reducing the scrap rate and improving production efficiency.

[0116] This geometric error calculation method is based on standardized measurement processes and instruments, and is easy to implement in industrial production. By formulating detailed measurement steps and operation specifications, the accuracy and consistency of the measurement results can be ensured.

[0117] In summary, the test bench of the present invention realizes high-precision measurement of the swing error; the setting of the positioning transition module effectively improves the test efficiency; the setting of the adjustable shim is suitable for complex environments and simplifies maintenance, enhancing the test accuracy and reliability of the test bench; the industrial control computer integrates a display and a key control area, with visualization, efficient interaction, safety control, and collaborative expansion capabilities, significantly enhancing the usability, reliability, and intelligent level of the test bench; the industrial control computer integrates a square box module, systematically solving the core problems such as reference drift, environmental interference, and data distortion in the swing test of a five-axis horizontal machining center.

[0118] The measurement method of the test bench of the present invention realizes high-precision measurement and evaluation; the comprehensive evaluation method can comprehensively reflect the geometric accuracy status of the machine tool, providing strong support for the performance evaluation and quality control of the machine tool; the flexibility of weight allocation makes the geometric error evaluation more in line with the actual processing requirements, improving the pertinence and effectiveness of component assembly to the whole machine assembly; through accurate geometric error evaluation, the accuracy status of the machine tool can be understood, so as to optimize the whole machine assembly work, improve the whole machine assembly efficiency and reduce the rework rate.

Claims

1. A five-axis horizontal machining center swivel head test bench, comprising a base (1), a column (2), and a swivel head (3); characterized in that: The base (1) is vertically and fixedly connected to the column (2), and the column (2) installs the pendulum head to be measured (3) through the positioning and transition module (4). The pendulum head to be measured (3) includes the main axis to be measured S (31) and the rotation axis to be measured A (32); several interference sensors are installed on the pendulum head to be measured (3), and the interference sensors are connected to the industrial control computer (5), and the industrial control computer (5) is used for closed-loop traceability detection of the module to be measured.

2. The test bench according to claim 1, characterized in that: The positioning and transition module (4) includes a connecting piece, a positioning pin, and an adjusting bolt.

3. The test bench according to claim 1 or 2, characterized in that: It further includes adjustable shims, and the adjustable shims are arranged at the bottom of the base (1).

4. The test bench according to claim 1, characterized in that: The industrial control computer (5) includes a display (51) and a key control area (52).

5. The test bench according to claim 1 or 4, characterized in that: The industrial control computer (5) includes a square box module (6).

6. The test bench according to claim 5, characterized in that: The square box module (6) is externally arranged on the upper horizontal plane of the base (1), or the direction module (6) is integrated with the industrial control computer (5).

7. The test bench according to claim 5, characterized in that: The industrial control computer (5) further includes an electrical system; the electrical system at least includes a power supply module, a power distribution module, a control module, a programming module, and a protection module.

8. A detection method for a swivel head test bench of a five-axis horizontal machining center, characterized in that: The test bench is the test bench according to any one of claims 1-7. After the column (2) of the test bench installs the pendulum head to be measured (3) through the positioning and transition module (4), the following detection contents are completed: S1. Measurement of the perpendicularity between the rotation axis A (32) and the main axis S (31); S2. Measurement of the deviation between the rotation axis A (32) and the main axis S (31); S3. Detection of the runout of the rotation axis A (32); The above detection steps are carried out simultaneously or sequentially, where the TCP accuracy is ±0.02 and shall not be lower than this accuracy; The test bench calculates the geometric error by the weighted average method.

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