Industrial Machine Straightness Error Correction
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Solution Overview
Problem
Industrial machines, such as position measuring devices, face challenges in maintaining precision due to changes in geometric errors caused by temperature fluctuations and time-related changes, particularly with straightness errors, which existing solutions fail to adequately correct without increasing costs or operational complexity.
Innovation Solution
An industrial machine equipped with a movement mechanism, a controller, and an angle detector that acquires angular errors to generate and apply straightness correction parameters, integrating pitching errors to correct straightness errors, enabling precise spatial corrections despite environmental and temporal changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high cost conditioning equipment is introduced to suppress changes in straightness error, then measurement precision is improved, but manufacturing cost and running cost increase
Solution Approach 1:
The system uses the existing angle detector to perform self-diagnosis and self-correction of straightness errors. The movement mechanism itself serves as the measurement tool by detecting angular errors at multiple positions and calculating straightness correction parameters, eliminating the need for external expensive conditioning equipment.
Solution Approach 2:
The patent replaces mechanical conditioning equipment with a computational approach. Instead of using physical devices to suppress thermal expansion and straightness errors, the system uses mathematical calculations to correct measurement values based on detected angular errors and environmental parameters.
2Measurement precision
If the rigidity of the movement means is increased to suppress changes in straightness error, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The system changes the approach from modifying physical parameters (increasing rigidity) to modifying measurement parameters. By detecting angular errors and applying computational corrections, the system achieves straightness error suppression without altering the physical properties or increasing the rigidity of the movement mechanism.
3Measurement precision
If an instrument such as straight edge and laser length detector is used to re-measure straightness error, then correction accuracy is improved, but cost and operation time increase
Solution Approach 1:
The angle detector serves multiple functions: it detects angular errors for calculating straightness correction parameters, detects rolling and pitching errors, and can be used for general position measurement. This multi-functionality eliminates the need for separate straight edge and laser length detector instruments, reducing both cost and operation time.
Solution Approach 2:
The patent merges the functions of multiple measurement instruments into a single integrated system. The angle detector combined with the controller performs what would traditionally require separate straight edge and laser length detector operations, consolidating the measurement process and reducing operational time.
4Device complexity
If correction parameters are calculated only at manufacturing time, then device complexity is reduced, but measurement precision deteriorates due to lack of consideration for changes in geometric errors
Solution Approach 1:
The system implements feedback by using the angle detector to continuously monitor angular errors during operation. The controller calculates straightness correction parameters based on real-time detection results, allowing the system to adapt to changes in geometric errors caused by thermal expansion and other environmental factors while maintaining a relatively simple structure.
Solution Approach 2:
The system performs preliminary calculation of straightness correction parameters using angular error data obtained during manufacturing or initial operation. These pre-calculated parameters are then applied during measurement operations, allowing the system to prepare correction data in advance while still accounting for geometric error changes.
Data Source
AI summary
According to an exemplary embodiment, an industrial machine includes: a movement mechanism configured to move along a specific axis direction; a controller configured to control the movement mechanism; and an angle detector configured to detect an angle of the movement mechanism about an axis perpendicular to the specific axis direction. The controller comprises: an angular error acquisition section configured to acquire angular errors of the movement mechanism for respective positions of the movement mechanism based on the angle detected when the movement mechanism is moved; a parameter generator configured to generate respective straightness correction parameters for correcting straightness errors of the movement mechanism in the specific axis direction by integrating the angular errors at the respective positions of the movement mechanism; and a correction section configured to correct movement errors of the movement mechanism based on the straightness correction parameters.