Machine Tool Dynamic Performance Assessment Using Sensor Nest
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Solution Overview
Problem
Existing machine tool performance analysis techniques fail to effectively assess the dynamic characteristics of numerically controlled machine tools, particularly under conditions of rapid motion and acceleration, which are crucial for precision machining but often overlooked in static or slow-moving tests.
Innovation Solution
The use of a sensor nest with orthogonal position sensors and a cubic reference block to measure dynamic performance by generating sinusoidal or other dynamic patterns of motion, allowing for the assessment of positional accuracy and cross-axis stability under dynamic conditions, and adjusting process parameters for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If static or slow-moving operational conditions are used for machine tool performance analysis, then measurement simplicity is maintained, but dynamic performance characteristics and positioning accuracy under rapid motion conditions cannot be assessed
Solution Approach 1:
The patent implements a nested measurement system where a sensor nest (containing multiple sensors) is positioned within a reference block, which itself is positioned on the machine tool. This nested structure allows comprehensive dynamic performance measurement while maintaining a compact, integrated measurement apparatus that does not interfere with machine operations.
Solution Approach 2:
The reference block serves as an intermediary element between the machine tool's moving components and the sensors. It provides a stable, precise reference frame that mediates the measurement process, allowing dynamic performance characteristics to be captured without the complexity of directly measuring moving parts.
2Reliability
If dynamic excitation commands with acceleration and deceleration components are used, then realistic operational conditions are simulated, but servo system limitations and mechanical deflections cause measurement errors
Solution Approach 1:
The system uses feedback by continuously comparing the commanded dynamic motion with the actual measured motion through the sensor nest. This feedback mechanism allows identification and correction of errors caused by servo system limitations and mechanical deflections, improving the reliability of performance assessment under realistic operational conditions.
Solution Approach 2:
The patent performs preliminary characterization of the machine tool's dynamic performance using the sensor nest and reference block before actual machining operations. This preliminary action identifies servo system limitations and mechanical deflection characteristics, allowing for compensation or optimization of machining parameters to maintain positioning accuracy.
Data Source
AI summary
Disclosed are various systems and methods for assessing and improving the capability of a machine tool. The disclosure applies to machine tools having at least one slide configured to move along a motion axis. Various patterns of dynamic excitation commands are employed to drive the one or more slides, typically involving repetitive short distance displacements. A quantification of a measurable merit of machine tool response to the one or more patterns of dynamic excitation commands is typically derived for the machine tool. Examples of measurable merits of machine tool performance include workpiece surface finish, and the ability to generate chips of the desired length.