A-axis Calibration for Five-Axis Oblique Machining Accuracy
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Solution Overview
Problem
Conventional five-axis machine tools are not suited for machining extrusion pin holes due to errors in the tilt angle of the spindle head and mechanical errors in the rotation angle of the table, leading to labor-intensive manual operations for oblique drilling.
Innovation Solution
A position ensuring system that measures and corrects the pivot angle of the spindle head and the rotation angle of the table using A-axis and C-axis calibration means, respectively, to ensure precise positioning during oblique machining, enabling automated high-precision machining by executing measurement and machining programs based on CAD data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional five-axis machine tools are used for oblique drilling of extrusion pin holes, then the high-speed and high-precision machining capabilities are not fully utilized, but the machining process becomes labor-intensive and time-consuming due to manual setup and drilling operations
Solution Approach 1:
The system performs preliminary measurement of the actual pivot angle and rotation angle errors before machining. By pre-measuring the A-axis pivot angle error and C-axis rotation angle error using calibration means, the system prepares correction data in advance, enabling automated compensation during subsequent machining operations without requiring manual intervention for each hole
Solution Approach 2:
The system implements feedback by measuring the actual angles with calibration means, comparing them with target values, and automatically correcting the errors. The measurement results feed back into the control system to adjust the pivot angle and rotation angle, creating a closed-loop control mechanism that eliminates manual operation requirements while maintaining high productivity
2Manufacturing precision
If manual setup and drilling operations are performed for each extrusion pin hole, then positioning accuracy can be achieved, but the manufacturing time is significantly increased
Solution Approach 1:
The system enables self-service by automating the entire measurement and correction process. The calibration means automatically measure the A-axis and C-axis errors, and the control system automatically applies corrections without requiring skilled workers to perform manual setup and positioning for each hole, thereby maintaining precision while eliminating time-consuming manual operations
Solution Approach 2:
The system changes the parameters by measuring and correcting the actual pivot angle and rotation angle deviations from their target values. By adjusting these angular parameters based on measured errors, the system achieves precise positioning automatically, eliminating the need for time-consuming manual setup while maintaining manufacturing precision
3Adaptability or versatility
If the spindle head is pivoted to meet the inclination of holes, then oblique machining capability is achieved, but error in the tilt angle occurs due to the weight of the spindle head
Solution Approach 1:
The system applies preliminary anti-action by measuring the tilt angle error caused by spindle head weight before machining begins. The calibration means measure the actual pivot angle, and the control system calculates correction values that counteract the gravitational effect, preventing the accuracy degradation that would occur during actual machining operations
Solution Approach 2:
The system uses feedback to continuously monitor and correct the tilt angle accuracy. By measuring the actual pivot angle with calibration means and comparing it with the target angle, the control system automatically adjusts the A-axis pivot angle to compensate for errors induced by spindle head weight, maintaining precision while preserving oblique machining capability
4Adaptability or versatility
If the table is rotated to meet the direction of holes, then multi-directional machining capability is achieved, but mechanical error in the rotation angle occurs
Solution Approach 1:
The system performs preliminary measurement of the C-axis rotation angle error using calibration means before machining operations. By measuring the actual rotation angle and calculating the deviation from the target angle in advance, the system prepares correction data that compensates for mechanical errors, enabling accurate multi-directional machining without sacrificing rotation angle precision
Solution Approach 2:
The system implements feedback by measuring the actual table rotation angle with calibration means, comparing it with the commanded angle, and automatically correcting the C-axis rotation. This closed-loop control maintains manufacturing precision while preserving the multi-directional machining capability provided by table rotation
Data Source
AI summary
A position ensuring system includes an A-axis calibration system which measures a displacement angle, which is an error between a target value and a measured value of the pivot angle of the spindle head about the A-axis, and corrects the pivot angle about the A-axis in such a manner that the displacement angle as measured with the corrected pivot angle as a target value fall within a tolerable range. A corrected data storage device stores the corrected pivot angle about the A-axis. An A-axis control system reads out the corrected pivot angle about the A-axis, the corrected pivot angle about the A-axis to pivot the spindle head when executing oblique machining of the inclined hole.