Accelerometer-Based Linear Motion Axis Straightness Measurement
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Solution Overview
Problem
Current methods for detecting the geometric accuracy of NC machine tools are inefficient due to large, expensive equipment and complex measurement processes, which hinder rapid and accurate assessment of linear motion axis precision, leading to potential machine tool wear and reduced production efficiency.
Innovation Solution
A rapid detection method utilizing accelerometers to measure acceleration perpendicular to the motion direction, employing quadratic time domain integration and filtering to calculate geometric accuracy, with a compact, low-cost device that simplifies installation and data processing, ensuring high Signal to Noise Ratio and efficient data fusion for accurate geometric accuracy calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser interferometers and ball bars are used to measure geometric accuracy, then measurement precision is improved, but measurement time increases and productivity decreases
Solution Approach 1:
The patent replaces traditional mechanical measurement systems (laser interferometers, ball bars) with an accelerometer-based measurement system. The accelerometer mounted on the linear motion axis measures acceleration signals, which are then integrated to obtain position and geometric accuracy data. This substitution of measurement principle dramatically reduces measurement time while maintaining acceptable precision for geometric accuracy assessment.
Solution Approach 2:
The measurement system utilizes the machine tool's own motion system to perform self-measurement. The accelerometer is mounted on the linear motion axis, and the axis moves through its travel range during normal operation, automatically generating the measurement data needed. This eliminates the need for separate, time-consuming measurement procedures and external measurement equipment.
2Measurement precision
If laser interferometers and ball bars are used to measure geometric accuracy, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex optical-mechanical measurement systems (laser interferometers requiring optical paths, mirrors, and precise alignment) with a simple accelerometer-based system. The accelerometer is a compact electronic sensor that directly measures acceleration without requiring complex optical setups, significantly reducing device complexity and cost.
Solution Approach 2:
The patent uses accelerometers, which are relatively inexpensive commercial off-the-shelf components compared to laser interferometers. While accelerometers have limited measurement ranges and require careful signal processing, their low cost and simplicity make them suitable for routine geometric accuracy monitoring where extreme precision is not required.
3Measurement precision
If laser interferometers and ball bars are used to measure geometric accuracy, then measurement precision is improved, but installation and debugging difficulty increase
Solution Approach 1:
The patent replaces the complex installation and alignment procedures of laser interferometers (requiring optical path setup, mirror positioning, and precise alignment) with simple accelerometer mounting. The accelerometer can be attached to the linear motion axis using standard mounting techniques, eliminating the need for complex optical alignment and debugging.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables rapid, accurate measurement of geometric accuracy with high resolution and low susceptibility to interference, improving measurement efficiency and reducing production downtime by using a compact, low-cost device that integrates easily with NC machine tools.
Implementation Method 1
An accelerometer is used to measure the acceleration information perpendicular to the direction of motion when the linear motion axis is in motion
Implementation Method 2
The quadratic time domain integral allows the motion axis deformation to be obtained
Data Source
AI summary
A rapid detection method for the geometric accuracy of the linear motion axis of an NC machine tool, uses accelerometers to measure the acceleration perpendicular to the direction of motion when the linear motion axis moves at a uniform speed. Firstly, the measuring device is mounted on the linear motion axis, and the upper measurement system automatically performs multi-channel acquisition and storage of the motion point acceleration data. Then, filter the acceleration data at the different speeds. Finally, the displacement data is obtained by quadratic integration of the filtered acceleration data in the time domain. Then calculate the straightness of the linear motion axis using the End Point Fit method, and complete the rapid measurement of the straightness of the linear motion axis of the machine tool. This can realize the rapid measurement of the geometric accuracy of the linear motion axis of the machine tool.