Optical Pose Control for Machine Tool End Element Alignment
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Solution Overview
Problem
Conventional methods for determining the relative pose between a machine tool's end element and workpiece are inaccurate due to geometric differences in machine components, leading to positioning errors and vibrations, which cannot be fully compensated for, especially in lightweight machine tools with high demands for precision and speed.
Innovation Solution
A method using an optical measuring system to detect multiple optical markers, calculate a correction value based on the relative pose comparison with a reference pose, and control the end element to minimize differences, allowing for precise alignment and compensation of kinematic deflections and geometric variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional position sensors in kinematic axes are used to determine relative pose, then the measurement system is simple and low cost, but geometric differences in machine components lead to positioning errors and reduced measurement precision
Solution Approach 1:
The patent replaces the conventional mechanical position sensor system with an optical measuring system that uses optical markers and cameras to detect positions. This substitution eliminates the need for mechanical sensors in the kinematic axes while achieving higher measurement precision by directly optically measuring the relative pose between tool and workpiece, compensating for geometric differences in machine components.
Solution Approach 2:
The patent uses optical markers that create optical copies or representations of the physical positions and orientations. By detecting these optical markers with cameras, the system obtains precise information about the relative pose without relying on mechanical sensors, thereby improving measurement precision while reducing dependence on complex mechanical measurement systems.
2Productivity
If lightweight machine tool structure is used to increase speed and reduce moving mass, then productivity and speed improve, but flexibility of components leads to positioning errors and reduced reliability
Solution Approach 1:
The patent implements a feedback mechanism where the optical measuring system continuously detects the actual relative pose between tool and workpiece during machining. The control system uses this feedback information to compensate for positioning errors caused by flexibility in the lightweight machine tool structure, thereby maintaining high positioning accuracy while benefiting from the speed and productivity advantages of the lightweight design.
Solution Approach 2:
The patent changes the measurement parameters by using optical detection instead of mechanical sensing, and dynamically adjusts for flexibility effects through real-time detection of marker positions. This allows the system to maintain reliable positioning accuracy despite the inherent flexibility of lightweight components, enabling both high speed and high precision.
3Productivity
If static and dynamic forces during machining are present, then the machining process is realistic and effective, but these forces cause deformation and vibrations leading to local movement between tool and workpiece
Solution Approach 1:
The optical measuring system provides real-time feedback on the actual relative pose during machining operations. This feedback captures the effects of static and dynamic forces, deformation, and vibrations, allowing the control system to compensate for these disturbances and maintain manufacturing precision while enabling effective machining processes.
Solution Approach 2:
The system performs periodic detection of optical markers during the machining process, continuously monitoring and compensating for forces-induced deformations and vibrations. This periodic measurement and correction cycle ensures that manufacturing precision is maintained throughout the machining operation despite the presence of dynamic forces.
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
This approach significantly reduces measurement costs, enables precise control of machine tools with smaller moving masses, enhances precision, and compensates for flexibility-related positioning errors, achieving high accuracy and dynamic performance.
Implementation Method 1
detecting multiple optical markers in a work environment of the machine tool by means of an optical measuring system
Data Source
AI summary
Provided is a method for the computerized control of an end element of a machine tool. The method includes a method step of sensing a plurality of optical markers in a work environment of the machine tool by means of an optical measuring system. The method includes a method step of determining a first relative pose between the end element and a workpiece on the basis of the plurality of sensed optical markers. The method includes a method step of determining a first correction value on the basis of a comparison of the first relative pose with a reference pose. The method includes a method step of controlling the end element for machining the workpiece taking the first correction value into consideration.