Calibration Ball Measurement for Five-Axis Rotary Unit Errors
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Solution Overview
Problem
Existing methods for calibrating rotary units in five-axis machine tools are inefficient and require manual interaction with dial indicators, leading to errors and complexity in measuring reference point lengths.
Innovation Solution
A measuring device with a movable component, calibration ball, and sensing switch, combined with a LRT detector and computing unit, automates the error calibration process by measuring spindle coordinates and calculating reference point lengths without manual dial indicators, using magnets for stability and tact switches for detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual dial indicators are used for calibration, then the calibration process can be performed, but the measurement accuracy is reduced and the process becomes complex
Solution Approach 1:
The patent replaces manual mechanical dial indicators with an automated optical measurement system. The LRT (Laser Radar Tester) detector captures images of the calibration ball, and coordinate information is extracted through image processing and fitting algorithms, eliminating manual reading errors and mechanical contact issues.
Solution Approach 2:
The measurement system performs self-calibration through automated image capture, coordinate extraction, and error calculation. The system automatically identifies the calibration ball position, calculates reference point lengths, and determines rotary unit errors without requiring manual intervention or external reference measurements.
2Productivity
If automated measurement systems are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The LRT detector serves multiple functions: it captures images of the calibration ball, extracts coordinate information through image processing, calculates reference point lengths, and determines rotary unit errors. This multi-functional approach consolidates what would otherwise require multiple separate devices into a single integrated system.
Solution Approach 2:
The calibration ball acts as an intermediary object that facilitates automated measurement. By placing markers on the calibration ball and using it as a reference target for the LRT detector, the system enables automated coordinate extraction and error calculation without direct mechanical contact or manual measurement.
3Reliability
If contact detectors are used, then calibration can be performed, but measurement errors increase due to manual interaction
Solution Approach 1:
The patent replaces contact-based mechanical dial indicators with non-contact optical measurement using the LRT detector. Image capture and digital coordinate extraction eliminate mechanical wear, contact forces, and manual reading errors, providing more reliable and precise measurements.
Solution Approach 2:
The system creates a digital copy of the calibration ball's position and dimensions through image capture and coordinate extraction. This digital representation allows for precise measurement and calculation without physical contact, eliminating errors associated with manual measurement and mechanical instrument interaction.
Data Source
AI summary
A measuring device and an error calibration method for a machine tool. The measuring device includes a housing, a movable component, a calibration ball and a sensing switch. The housing has an inner space. The movable component is movably disposed in the inner space. The calibration ball is disposed on an end of the movable component and at least partially located outside the housing. The sensing switch is disposed in the inner space and configured to detect a movement of the movable component relative to the housing.