Machine Tool Circular Error Compensation for Faster Adjustment
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Solution Overview
Problem
Machine tools experience increased circular errors over time due to adverse working environments, which exceed initial tolerance limits, necessitating re-testing and manual adjustment of controller parameters, without considering the actual end condition of the machine tool mechanism.
Innovation Solution
A machine tool adjustment method and system that performs multiple circular tests, analyzes error conditions using a processor and memory with error analysis and compensation modules, automatically determining and compensating for errors, optimizing parameters to meet predetermined criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of controller parameters is performed repeatedly, then machining accuracy can be improved, but adjustment time increases significantly
Solution Approach 1:
The system enables the machine tool to automatically perform circular tests, automatically obtain measured error values from measuring instruments, automatically determine error conditions, and automatically define compensation parameters without requiring manual intervention. The processor automatically executes the error analysis module and error compensation module to complete the entire adjustment process autonomously, eliminating the need for repeated manual parameter adjustments while maintaining high machining accuracy
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the machine tool performs circular tests, the measuring instruments obtain measured error values, the processor analyzes these errors to determine error conditions, and compensation parameters are automatically defined based on the analysis results. This feedback loop continues iteratively until the error condition meets predetermined criteria, ensuring high machining accuracy while reducing adjustment time through automated iterative optimization
2Manufacturing precision
If conventional manual adjustment process is used, then error compensation can be achieved, but the actual end condition of the machine tool mechanism is not considered
Solution Approach 1:
The system replaces manual mechanical adjustment with an automated electronic control system. The processor executes software modules (error analysis module and error compensation module) that automatically analyze measured error values and define compensation parameters. This substitution of manual mechanical processes with automated electronic control and software-based error analysis enables more precise consideration of the actual end conditions of the machine tool mechanism, as the system can process and respond to measured error data more accurately and comprehensively than manual methods
Solution Approach 2:
The system introduces a measuring instrument as an intermediary between the machine tool mechanism and the control system. The measuring instrument objectively measures the actual circular trajectory and provides measured error values to the processor. This intermediary enables accurate detection of the actual end condition of the machine tool mechanism by bridging the gap between the physical mechanism and the digital control system, allowing for precise error analysis and compensation parameter definition
Data Source
AI summary
This disclosure provides a machine tool adjustment method and system thereof. The machine tool adjustment method includes the following steps: enabling a machine tool to perform a circular test; obtaining a measured error value Em from a measuring instrument, and the measured error value Em is defined by the difference between the actual circular trajectory and the preset circular trajectory during the circular test; determining an error condition of the tool machine from the measured error value Em; determining whether the error condition is less than a predetermined criteria; if not, defining a compensation parameter according to the error condition and enabling the machine tool to perform another circular test according to the set compensation parameter until the error condition is less than the predetermined criteria; and if yes, ending the circular test and the machine tool adjustment is finished.