3D Displacement Sensing for Multiaxis Machining Compensation
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Solution Overview
Problem
Existing multiaxis machining devices face challenges in maintaining machining performance repeatability due to accumulated errors from thermal deformation, stress deformation, and abrasion, which conventional thermal deformation control technologies struggle to compensate effectively, especially when ambient temperature and heating characteristics change.
Innovation Solution
A three-dimensional displacement sensor system is introduced, comprising secure elements with displacement sensing components and a signal processor, measuring x, y, and z-axis displacements to correct deformation effects, using coherent light sources, light sensors, and laser confocal displacement sensors to provide real-time positioning and compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermal deformation control technology is used to measure temperature change and calculate real-time thermal deformation, then thermal compensation can be achieved, but the sampling range is limited and calculation errors occur when heating characteristics or ambient temperature change, reducing accuracy and machining stability
Solution Approach 1:
The patent replaces the software-based thermal deformation calculation system with a physical measurement system using displacement sensors. Instead of calculating thermal deformation from temperature data, the system directly measures actual displacement caused by thermal and other deformations, eliminating calculation errors and improving both accuracy and adaptability to changing conditions
Solution Approach 2:
The patent introduces displacement sensors as intermediary measurement devices between the machine tool components and the control system. These sensors directly measure the actual displacement of machine components, providing accurate real-time data that reflects the combined effects of thermal deformation, stress deformation, and abrasion without requiring complex calculations
2Reliability
If conventional thermal deformation control technology is used, then some thermal compensation can be achieved, but excessive errors from thermal deformation, stress deformation, and abrasion cannot be effectively compensated, reducing machining performance repeatability
Solution Approach 1:
The patent replaces the indirect thermal compensation method with direct displacement measurement. By using displacement sensors to measure actual position changes of machine components, the system can compensate for all sources of error (thermal, stress, and abrasion deformations) rather than only thermal effects, significantly improving both reliability and manufacturing precision
Solution Approach 2:
The patent implements a feedback control system where displacement sensors continuously measure the actual positions of machine components and feed this information back to the control system. The control system then adjusts the machine tool operations based on this real-time feedback, enabling effective compensation for accumulated errors and maintaining machining performance repeatability
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 system effectively eliminates various deformation effects, ensuring high positioning accuracy and repeatability by accurately measuring and compensating for thermal, stress, and abrasion deformations, thereby maintaining consistent machining quality across multiple workpieces.
Implementation Method 1
The first light source sensor measures bright spots generated by irradiation from the first coherent light source to an object under test
Implementation Method 2
The third displacement sensing component is a laser confocal displacement sensor, a color confocal displacement sensor, a white light interference displacement sensor, or a triangulation laser displacement sensor
Data Source
AI summary
The present invention provides a planar three-dimensional displacement sensor for a multiaxis machining device. With the measurement of the (planar) three-dimensional displacement sensor in the multiaxis machining device, the multiaxis machining device and a multiaxis machining compensation method are able to eliminate various deformation effects effectively.