Machine Tool Calibration Control for Flexure Error Correction
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Solution Overview
Problem
Current machining technologies face challenges in accurately correcting machining errors during the machining process, leading to inaccuracies in workpiece production due to tool displacement and flexure issues.
Innovation Solution
A control device for industrial machines that includes a relative displacement-specifying unit, contact determination unit, and tool data correction unit, utilizing camera images and strain sensor measurements to determine tool position and correct tool data, thereby generating control commands to adjust for machining errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tool displacement and flexure are not corrected, then machining speed and productivity are maintained, but machining precision deteriorates due to accumulated errors
Solution Approach 1:
The system performs preliminary calibration by capturing images of calibration patterns at known positions before machining begins. This establishes reference data for tool position and displacement compensation, allowing the system to pre-correct for anticipated errors rather than reacting to them during machining.
Solution Approach 2:
The system continuously monitors tool position using vision sensors and strain sensors during machining operations. Real-time feedback from these sensors allows the control device to dynamically adjust tool path compensation, correcting displacement and flexure errors as they occur rather than allowing them to accumulate.
2Measurement precision
If real-time tool position monitoring is implemented, then machining accuracy is improved, but measurement precision requirements increase and system complexity worsens
Solution Approach 1:
The system introduces vision sensors as an intermediary measurement tool that captures images of calibration patterns and tool positions. These optical measurements are then processed through image recognition algorithms to extract precise position data, serving as a mediator between physical tool position and digital control data.
Solution Approach 2:
The system replaces traditional mechanical measurement systems with vision-based optical measurement. Instead of using complex mechanical encoders or laser interferometers, the system uses cameras to capture images and computationally determine tool position, simplifying the physical measurement infrastructure while maintaining precision.
3Manufacturing precision
If tool length compensation is performed frequently, then machining precision is maintained, but processing time increases and productivity decreases
Solution Approach 1:
The system performs tool length measurement and compensation data calculation in advance during setup or idle periods, storing this compensation data for later use. This preliminary preparation eliminates the need for time-consuming measurements during active machining operations.
Solution Approach 2:
Instead of continuously measuring tool length, the system performs measurements periodically at predetermined intervals or when specific conditions are met (such as tool changes or after a certain number of machining cycles). This periodic approach maintains precision while minimizing interruptions to productivity.
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
The control device effectively corrects machining errors by accurately determining tool contact with the workpiece and adjusting tool data, improving machining accuracy and reducing uncut portions, even in the presence of machine vibrations.
Implementation Method 1
a measurement value related to flexure of the main shaft
Implementation Method 2
a captured image of the jig calibration point and a captured image of the tool calibration point imaged by a camera
Data Source
AI summary
A relative displacement-specifying unit specifies relative displacement between a jig and tool based on measurement values of displacements of the tool and jig. A position determination unit determines whether the jig and the tool are positioned at jig and tool calibration points based on the measurement values. A displacement correction unit corrects the measurement values based on captured images of the jig and tool calibration points when it is determined that the jig and the tool are positioned at the calibration points. A contact determination unit determines whether the tool contacts the workpiece based on a measurement value related to main shaft flexure. A tool data correction unit corrects tool data based on the relative displacement when it is determined that the tool contacts the workpiece. A control unit generates a control command to control the jig or the tool based on the relative displacement, workpiece shape, and tool data.