Machine tool precision determination and compensation approaches Review on research at wbk Institute of Production Science

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1 Machine tool precision determination and compensation approaches Review on research at wbk Institute of Production Science Daniel Brabandt London, 5th Nov wbk Institute of Production Science KIT University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association

2 Agenda Introduction Intrinsic Part Scale Adaptronical Strut Mechatronic Clamping System Summary Slide 2

3 wbk Institute of Production Science Karlsruhe Institute of Technology (KIT) Established: 1 October 2009 Courses of Studies: 44 Students: Staff: (including 346 professors) Total budget: 795 m Objectives Positioning the Institute as an institution of internationally outstanding research and teaching in natural sciences and engineering that offers scientific excellence and world class performance in Research Education Innovation Slide 3

4 wbk Institute of Production Science Locations wbk at Fasanengarten Production systems Machines, equipment and process automation wbk at Ehrenhof Manufacturing and materials technology wbk at Campus Nord GAMI - Global Advanced Manufacturing Institute Suzhou, China AMTC - Advanced Manufacturing Technology Center Shanghai, Jiading Campus at Tongji University, China wbk, Fasanengarten, KIT wbk, Ehrenhof, KIT Building 276, KIT Campus Nord Tongji University, GAMI, China Slide 4

5 wbk Institute of Production Science Research Portfolio Prof. Dr.-Ing. Jürgen Fleischer Prof. Dr.-Ing. Gisela Lanza Prof. Dr.-Ing. habil. Volker Schulze Slide 5

6 Introduction Accuracy of machine tools Accuracies of machine tools is determined by all of the components and their errors Approaches to improve accuracies: Error compensation within machine tool structure: Adaptronic strut Error compensation at the tool: Compensation in tool clamping Workpiece orientation: Intrinsic part Scale Slide 6

7 Agenda Introduction Intrinsic Part Scale Adaptronical Strut Mechatronic Clamping System Summary Slide 7

8 Intrinsic part scale Motivation and Introduction Aim Flexible and exact machining of space-frame structures in automated small batch production BMW C1 Process insertion and positioning the profile into the clamping fixture with an industrial robot (IR) local clamping of the profile sequential machining Slide 8

9 Intrinsic part scale Profile positioning in the clamping fixture Positioning 4 DOF are constrained with mechanical stops profile displacement and rotation along the longitudinal axis by the IR mechanical stops Inaccurate positioning due to displacements inside the IR-gripper limited accuracy of the IR profile contour deviations IR-gripper curved profile Metrological approach individual laser markings on the profile surface for a component-specific scale Slide 9

10 Intrinsic part scale Component-specific scale Required information in the marking x, y coordinates rotation-angle α (centerline camera CS) orientation absolute allocation camera CS Y X α (x,y, direction) camera view profile Geometry derivation evaluation of simple ruled geometries and their combinations Scheme: considered requirements marking process detection process Binary image: repeat accuracy of the position-detection of a single marking: ± 1.2µm (6σ) Slide 10

11 Intrinsic part scale Marking process Off-line marking inside of a millingmachine positioning and focusing with axis and control of the milling machine during marking-process idle In process marking on the fly synchronous with extrusion process (with marking laser) marking on the fly compensation of profile inclination real time control Additional Axis Marking Laser Slide 11

12 Intrinsic part scale Measuring station Profile positioning positioning of two markings Setup 1 2 calculation of deviation to the default marking position calculation of projected distance measuring the contour of the segment Scatter plot stepwise contour detection with a 2D laser-line triangulation sensor calculation of peak coordinates (x,y,z) by fitting an ellipse with least square method Slide 12

13 Intrinsic part scale Metrological approach Overall contour determination generate overlapping areas between two segments align splines in overlapping areas calculate the overall contour by means of cubic spline interpolation coordinate system located in last link z overlapping area reference markings z 4 x segment 1 segment 2 y y x z y x z y x z z y x y x x y schematic determination of the entire profile contour z Slide 13

14 Intrinsic part scale Validation (results of a planar curved profile) xy-plane 1 y reference values measurement results 2 z x marking positions measurement results reference values circular cross-section Ø40x2mm profile with 6 Segments Segment length: 250mm total length: 1500mm overlap length: ± 60mm 12 measurements reference values and measurement results average deviation Slide 14

15 Intrinsic part scale Validation (results of a planar curved profile) xz-plane 1 y average deviation 2 3 z x marking positions reference values measurement results max. contour deviation xy plane: - 0.5mm; xz plane: - 0.4mm maximum dispersion: Δxy= ± 0.15mm Δxz= ± 0.25mm positioning accuracy over 6 segments (Δl= mm): absolute: mm standard deviation: σ x = 6µm Slide 15

16 Intrinsic part scale Summary approach for exact profile positioning and contour detection on the basis of a component specific scale metrological approach and design of single markings experimental setup and results of planar curved profile approach is usable for the precise and flexible positioning and contour detection of curved profiles (e.g. for machining processes) Slide 16

17 Agenda Introduction Intrinsic Part Scale Adaptronical Strut Mechatronic Clamping System Summary Slide 17

18 Adaptronical Strut Introduction Influences on accuracy of machine tools Mechanical stiffness and production accuracy of machine components are two main factors which influence the geometrical accuracy of machine tools. Process loads and errors in machine components lead to a displacement of Tool Center Point. Negative impact on machining accuracy Approach: Improvement of mechanical stiffness through adaptronics Parallel kinematic machine tool with three degrees of freedom Slide 18

19 Adaptronical Strut Approach Integration of an adaptronical strut The strut must be able to compensate deformations of the mechanical components from external loads To increase stiffness of a machine structure, the strut needs to detect a change in load carry out correction movements The Approach for the adaptronical strut is based on the principle of oscillatingwire balance. Concept of the adaptronical strut Slide 19

20 Adaptronical Strut Prototypical Realisation Control concept To realize the functionality of the strut a special control concept is necessary Separation of sensor and actuator signals Stimulation of vibrating string Control of actuator stroke Simplified control concept Prototypical adaptronical strut The structure consist of an upper and a lower part Coaxially piezoelectric transducer Vibration string Prototypical adaptronical strut Slide 20

21 Adaptronical Strut Results and Summary Measurements and Validation Frequency band Hz Response time ms Resulting stiffness 11 KN/ µm An approach has been developed and implemented for improving the mechanical stiffness of an strut structure for parallel kinematics through adaptronics. The approach can be applied to other structures in machine tool manufacturing in principle Slide 21

22 Agenda Introduction Intrinsic Part Scale Adaptronical Strut Mechatronic Clamping System Summary Slide 22

23 Mechatronic Clamping System Introduction Micro-Milling Application area Very small components Ultra precise geometries Micro specific challenges Tool deflection Relatively high cutting edge radii Cutting edge displacement <1 µm 18 µm 10 µm 6 µm 2 µm aim = cutting edge displacement + tool tolerance + fit errors clamping sytem concentricity error spindle Cutting edge displacement caused by concentricity errors in the spindle, fitting errors in the clamping system and material tolerances. The main problem is the unpredictability of the wobbling move of the tool. Slide 23

24 Mechatronic Clamping System Introduction Cutting edge displacement ideal: diameter = 50 µm displacement = 0 µm real: diameter = 50 µm displacement = 20 µm h displacement h Worst case scenario: one cutting edge is completely unloded, the opposite edge however has doubled loads. Slide 24

25 Mechatronic Clamping System Compensation Problems due to cutting edge displacement Doubled load for one cutting edge ( tool with 2 cutting edges) Therefore decreased tool lifetime Decreasing process stability Approach Mechatronic clamping system for compensation at nominal speed Idea: cutting edge displacement compensation Slide 25

26 Mechatronic Clamping System Compensation Coils for energy transfer Actuation through piezo actuators Flexibility with solid-state joint Contactless energy transfer runs a piezo actuater to tilt the flexible, lower part. The solid-state joint enables the tilt ot the chuck to direct the tool center point to its nominal point. A feasible maximum of µm correction is possible. Slide 26

27 Mechatronic Clamping System Operation measurement analysis compensation Detection of tumbling cutting edges with a Blum-laser. Alternating shading of the laser triggers compensation. Slide 27

28 Mechatronic Clamping System Validation and results 255,81 µm 241,78 µm grooves grooves 225,72 µm 224,75 µm 239,18 µm 241,17 µm bars not compensated bars compensated Nominal size: 240µm Compensation enables manufacturability of tolerable deviations from the nominal size. Slide 28

29 Mechatronic Clamping System Validation and results 50 test runs uncompensated 35 µm 10 µm 50 test runs compensated <5 µm Slide 29

30 Agenda Introduction Intrinsic Part Scale Adaptronical Strut Mechatronic Clamping System Summary Slide 30

31 Introduction Accuracy of machine tools Adaptronic strut Compensation in tool clamping Intrinsic part Scale Accuracies of machine tools is determined by all of the components and their errors Increase of machine tool accuracy is possible by scientific approaches using measuring systems Slide 31

32 Thank you! Dipl.-Ing. Daniel Brabandt Research Associate Kaiserstr. 12, Karlsruhe Tel.: Thanks to: F. Zanger, P. Hoppen, M. Deuchert, S. Dosch, J. Bauer, D. Berger Slide 32

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