Machine Tool Calibration Control for Real-Time Machining Accuracy
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Solution Overview
Problem
Existing machining technologies struggle to accurately correct machining errors during the processing of workpieces, leading to inaccuracies in the finished product.
Innovation Solution
A control device for industrial machines that includes a relative displacement specification unit, position determination unit, displacement correction unit, contact determination unit, and tool length correction unit, which utilize measurement data and image processing to adjust the relative positions of the jig and tool, determine contact with the workpiece, and correct tool length to improve machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining control is used, then the machining process is simple, but machining accuracy deteriorates due to inability to correct errors in real-time
Solution Approach 1:
The system performs preliminary calibration by capturing images of calibration points on the jig and tool before machining begins. This preliminary action establishes the relationship between camera coordinates and machine coordinates, enabling subsequent real-time correction of machining errors without adding complexity to the actual machining process.
Solution Approach 2:
The system continuously monitors the actual positions of the jig and tool during machining using the calibrated camera system. By comparing actual positions with target positions, the system generates feedback signals that enable real-time correction of machining errors, improving accuracy without requiring complex manual intervention.
2Manufacturing precision
If real-time error correction is implemented, then machining accuracy improves, but measurement and position determination complexity increases
Solution Approach 1:
The system introduces calibration points as intermediary markers placed on the jig and tool. These calibration points serve as mediators between the camera observation system and the actual machining components, simplifying position measurement by providing easily detectable reference features that enable accurate coordinate transformation without complex direct measurement of the tool and jig themselves.
Solution Approach 2:
The system creates a visual copy of the physical machining system by capturing images of calibration points with a camera. This optical copy enables non-contact, high-precision position measurement and facilitates real-time monitoring and correction of machining errors without interfering with the physical machining process or requiring complex tactile measurement systems.
3Manufacturing precision
If tool length correction is performed, then machining precision improves, but the control process becomes more complex
Solution Approach 1:
The system enables the machining equipment to self-correct for tool length variations by automatically calculating correction values based on image measurements of calibration points. The control device autonomously determines the actual tool length, compares it with the programmed tool length, and generates correction commands without requiring manual measurement or external intervention, thereby improving precision while keeping the control process manageable.
Data Source
AI summary
A relative displacement specification unit specifies a relative displacement between a jig and a tool. A position determination unit determines whether the jig and the tool are respectively positioned at a jig calibration point and a tool calibration point. A displacement correction unit corrects the measurement values of the displacements of the jig and the tool. A contact determination unit determines whether the tool has come into contact with a workpiece based on a measurement value related to a deflection of the tool. A tool length correction unit corrects tool length data based on the relative displacement when the tool is determined to have come into contact with the workpiece. A control unit generates a control command for controlling the jig or tool based on the relative displacement, a shape of the workpiece, and tool length data indicating a length of the tool.