Machine Tool Thermal Error Measurement With Optical Ball Lens Targets
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Solution Overview
Problem
Current machine tool thermal deformation measurement methods are time-consuming, labor-intensive, and imprecise, particularly during hot running tests, due to manual data recording and limited single-shaft measurement capabilities.
Innovation Solution
A drive system thermal temperature rise test and compensation system that uses an optical non-contact sensor and temperature sensors to measure and record displacement errors electronically, enabling multiaxial measurements and temperature data collection for accurate compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual measurement and recording methods are used, then the measurement process is simple and easy to implement, but the data recording is time-consuming and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical measurement system with an automated optical measurement system. The optical sensor group non-contactly measures the position of the main shaft, and the signal processor automatically records displacement errors, eliminating the need for manual reading and recording operations.
Solution Approach 2:
The measurement system performs self-recording of data through the signal processor, which automatically captures and stores the displacement error values without requiring external manual intervention for data documentation.
2Device complexity
If a single dial gauge is used for measurement, then the device is simple, but it can only measure one shaft and requires frequent repositioning
Solution Approach 1:
The optical sensor group is designed with multiple sensors that can simultaneously measure multiple shafts or measurement points. This multi-functional configuration allows the system to measure different shafts without requiring physical repositioning of the measurement device.
Solution Approach 2:
Multiple optical sensors are combined into a single sensor group that functions as an integrated measurement unit, allowing simultaneous multi-point measurement while maintaining a unified device structure.
3Ease of manufacture
If manual reading and recording is performed, then the equipment cost is low, but measurement precision and accuracy are poor
Solution Approach 1:
The patent replaces manual reading operations with automated optical sensing and electronic signal processing. The optical sensor group provides non-contact, high-precision measurement of the main shaft position, and the signal processor accurately calculates displacement errors, significantly improving measurement precision.
Solution Approach 2:
The system creates an optical copy or representation of the physical shaft position through light interaction with the ball lens, allowing precise digital measurement and recording without physical contact or manual intervention.
4Device complexity
If frequent repositioning of the dial gauge is required, then a single measurement device is used, but the measurement process becomes time-consuming
Solution Approach 1:
The optical sensor group is designed as a universal measurement device that can measure multiple shafts and positions simultaneously. This eliminates the need for frequent repositioning and enables continuous measurement operations, significantly improving measurement productivity.
Solution Approach 2:
The system enables continuous measurement operations by maintaining the sensor group in a fixed position while measuring multiple shafts sequentially or simultaneously, eliminating interruptions caused by repositioning and maintaining continuous useful measurement action.
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
Facilitates quick, precise, and automated data recording of thermal deformations across multiple axes, allowing for long-term measurements and improved compensation for thermal errors in machine tools.
Implementation Method 1
an optical non-contact type sensor group is surroundingly provided on the bracket, and a sensing center is formed in the center of the sensor group
Implementation Method 2
more than one temperature sensors respectively combined with the transmission device of the machine tool, wherein each of the temperature sensors are used to measure temperature and transmit temperature data externally
Data Source
AI summary
A drive system thermal temperature rise test and compensation system. The system has an optical non-contact type sensing head mounted on a main shaft of a machine tool, and a sensing center is formed in the center of the sensing head. A platform driven by a transmission device of the machine tool is provided with plural ball lens devices, and a temperature sensor for transmitting temperature data externally is further provided on the transmission device. After the machine tool sequentially records an original point coordinate for each ball lens center by using the sensing head, the sensing head is cyclically and sequentially moved to the original point coordinate of each ball lens, so as to measure a displacement error between the sensing center and the ball lens center resulted from thermal shifts of the transmission device, as well as capable of measuring multiaxial errors and using various axial temperatures for compensation.