Production Machine Axis Calibration via Single-Path Measurement
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Solution Overview
Problem
Current calibration methods for production machines with position-controlled axes are time-consuming and expensive, requiring multiple approached positions and large equation systems to determine length deviations, zero-position errors, and axial misalignments.
Innovation Solution
A method that involves moving each machine axis once along a specified travel range, using measuring equipment like laser trackers to record and analyze paths, and correcting model parameters based on analysis results, allowing for efficient calibration of multiple axes in a kinematic chain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods using multiple approached positions and large equation systems are used, then measurement precision is improved, but loss of time and productivity deteriorate
Solution Approach 1:
The patent extracts and eliminates unnecessary calibration steps by moving only one axis at a time through its complete travel range, rather than requiring all axes to be moved to multiple reference positions. This extraction of essential calibration actions reduces the number of measurement points from many (traditional method) to just one per axis (invention), thereby maintaining calibration accuracy while dramatically reducing calibration time
Solution Approach 2:
The calibration process is segmented into independent axis-by-axis calibration steps. Each axis is calibrated separately by moving it through its complete travel range while keeping other axes stationary, allowing the calibration of one axis to be performed without affecting others. This segmentation enables parallel processing and reduces the computational complexity from solving large simultaneous equation systems to solving smaller, independent equations for each axis
2Manufacturing precision
If traditional calibration methods with multiple reference positions are used, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The patent extracts the essential calibration information by using only one reference position per axis (the complete travel range from minimum to maximum), eliminating the need for multiple reference positions and the complex network of equations that connects them. This extraction simplifies the calibration procedure while preserving the ability to determine length deviations, zero-position errors, and axial misalignments accurately
Solution Approach 2:
Instead of moving multiple axes to multiple reference positions and then solving large equation systems to back-calculate errors (traditional approach), the invention inverts the approach by moving one axis at a time through its complete range and directly measuring the deviations, thereby directly obtaining calibration parameters without complex mathematical inversion
3Productivity
If automated calibration is implemented, then productivity is improved, but device complexity deteriorates
Solution Approach 1:
The calibration system performs self-calibration by automatically moving each axis through its complete travel range and measuring the actual positions using the control facility's existing measurement capabilities. The system independently determines its own calibration parameters without requiring external calibration equipment or complex additional hardware, thereby achieving high productivity while minimizing the increase in device complexity
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 approach significantly reduces the computational effort and time required for calibration while achieving high accuracy, making it suitable for production machines with linear, rotary, or combined axes, and enabling automatic calibration without manual specification of reference points.
Implementation Method 1
measuring equipment, in particular a laser tracker, for determining a path which describes a specific point that is assigned to the first machine element during a movement of the first machine element
Data Source
AI summary
A production machine system includes a production machine having multiple axes and drives. Each drive adjusts a machine element relative to a further machine element with respect to an axis. The machine elements separate the drives from each other, with the drives and the machine elements forming a kinematic chain. A control facility controls the drives to move the machine element relative to the further machine element. A model of the machine element is stored in the control facility and comprises a model parameter of the machine element. A measuring equipment determines a path describing a specific point assigned to the machine element during movement of the machine element. An analysis equipment analyzes the specific path and a correction equipment corrects the model parameter based on the analysis result. To determine the specific path, several, in particular all axes are moved successively starting from a base along the kinematic chain.