Rotary Shaft Angle Calibration Using Digital Twin and Sensor Substitution
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Solution Overview
Problem
Existing methods for angle calibration of rotary shafts in machine tools lack precision and require dedicated equipment, as they rely on less accurate angular sensors for calibration.
Innovation Solution
A method involving a more precise calibrating angular sensor is attached to a rotary shaft, allowing it to replace the controlling angular sensor of another shaft, enabling the calculation and storage of a calibration value by a control unit, which detects the difference in angles between the controlling and calibrating sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high-precision angle measuring system is attached to the rotary table for calibration, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a digital twin model that replicates the physical rotary table's geometric parameters, measurement data, and calibration information in a virtual environment. This digital copy allows calibration operations to be performed virtually, eliminating the need for complex physical measurement systems while maintaining calibration precision.
Solution Approach 2:
The patent replaces traditional mechanical angle measuring systems with an information-based approach using sensors, processors, and digital modeling. The calibration process transitions from mechanical measurement to computational analysis of sensor data against the digital twin model, reducing mechanical complexity.
2Measurement precision
If a dedicated angle reader or computer is used for calibration, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent enables the machine tool's existing control system to perform its own calibration by comparing sensor measurements against its digital twin model. The system self-diagnoses and self-calibrates without requiring external dedicated calibration equipment, making the calibration process integrated and self-sufficient.
Solution Approach 2:
The patent makes the existing control system and sensors serve dual purposes: both for normal machine operation and for calibration functions. The same sensors and processors used for manufacturing control are also used for calibration, eliminating the need for separate dedicated calibration equipment.
3Device complexity
If traditional angle calibration methods are used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent pre-establishes a digital twin model containing the rotary table's ideal geometric parameters and characteristics before calibration is needed. This preliminary digital model serves as a reference standard, enabling accurate calibration without requiring complex physical measurement equipment during the actual calibration process.
Solution Approach 2:
By creating and storing a digital copy of the rotary table's geometric characteristics, the system enables precise calibration through data comparison rather than physical measurement. The digital twin acts as a virtual reference that simplifies the calibration process while maintaining high precision through computational accuracy.
Data Source
AI summary
Provided is a method for angle calibration of a rotary shaft, including: attaching a calibrating angular sensor to a first rotary shaft of an industrial machine including a plurality of rotary shafts and a control unit that controls the rotary shafts based on an angle detected by a controlling angular sensor provided for each rotary shaft, the calibrating angular sensor being more precise than the controlling angular sensor; connecting the calibrating angular sensor in place of the controlling angular sensor of a second rotary shaft; rotating the first rotary shaft; calculating a difference between a first angle of the first rotary shaft detected by the controlling angular sensor and a second angle of the first rotary shaft detected by the calibrating angular sensor; and storing the calculated difference as a calibration value for an angle of rotation of the first rotary shaft.