Thermal Error Compensation for Mechanical Process Calibration Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mechanical processes, such as those in coordinate measuring machines and articulated robot arms, face challenges in predicting and compensating for thermal errors caused by thermal gradients and temperature changes, which are difficult to mitigate using traditional calibration methods, especially when data availability varies across similar processes.
Innovation Solution
A computer program product and method that learns a thermal error compensation function from empirical and synthetic data, using a model with free and internal parameters to adapt a representation input function, which can be applied to similar mechanical processes to optimize sensor placement and compensation, leveraging transfer learning for improved thermal error compensation across different environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional calibration methods are used to compensate thermal errors, then thermal error compensation is provided for calibrated evolutions, but different uncalibrated evolutions cannot be compensated
Solution Approach 1:
The patent creates a universal thermal error compensation model that can handle multiple different evolutions of the mechanical process. The system uses a library of evolution functions with different parameters that can describe various thermal behaviors, allowing the same compensation framework to work across different operating conditions without requiring separate calibration for each evolution.
Solution Approach 2:
The system changes parameters of evolution functions to adapt to different thermal scenarios. By adjusting parameters such as thermal coefficients, time constants, and gradient factors within the evolution functions, the model can accurately represent different thermal evolutions while maintaining a unified compensation approach.
2Loss of information
If sensors are added to capture more thermal error information, then diagnostic information improves, but device complexity increases
Solution Approach 1:
The patent extracts essential thermal information from a limited set of sensor measurements by using evolution functions that model the thermal behavior over time. Instead of requiring comprehensive sensor coverage, the system extracts key thermal characteristics (such as temperature trends, gradients, and rates of change) from minimal sensor data and uses mathematical models to infer the complete thermal state.
Solution Approach 2:
Evolution functions serve as intermediaries between physical sensors and thermal error compensation. These mathematical models act as mediators that transform limited sensor readings into comprehensive thermal error information, bridging the gap between simple measurements and complex thermal behavior without requiring additional physical sensors.
3Measurement precision
If extensive training data is collected for thermal error compensation, then compensation accuracy improves, but data acquisition time and resources increase
Solution Approach 1:
The system performs preliminary characterization of thermal behavior using a limited set of evolution functions and parameters. By pre-defining the mathematical forms of thermal evolutions and their parameters, the system reduces the need for extensive training data during operation. The evolution functions are designed to capture essential thermal patterns with minimal data requirements.
Solution Approach 2:
The patent uses dynamic evolution functions that can adapt to changing thermal conditions without requiring retraining. The functions incorporate time-dependent parameters and can adjust to different thermal scenarios dynamically, reducing the need for large static training datasets while maintaining accuracy across varying operating conditions.
Data Source
AI summary
A computer program product and to a method for compensating thermal errors in a mechanical process, the mechanical process in particular provided by a mechanical device such as a coordinate measuring machine, a tooling machine or an articulated robot arm. Thermal errors arise due to thermal disturbances affecting the mechanical process, wherein thermal disturbances may arise from environmental influences affecting the mechanical process or from internally generated changing temperature distributions.