Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding compo...Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding components,result in dimensional deviations that can lead to poor part quality and reduced precision in high-speed manufacturing processes.This paper explores thermal error modeling and compensation methods for the spindle of five-axis CNC machine tools.A detailed analysis of the heat generation,transfer mechanisms,and finite element analysis(FEA)is presented to develop accurate thermal error models.Compensation techniques,such as model-based methods,sensor-based methods,real-time compensation algorithms,and hybrid approaches,are critically reviewed.This study also discusses the challenges in real-time compensation and the integration of thermal error compensation with machine tool control systems.The objective is to provide a comprehensive understanding of thermal error phenomena and their compensation strategies,ultimately contributing to the enhancement of machining accuracy in advanced manufacturing applications.展开更多
Industrial robots are integral to modern manufacturing systems,enabling high precision,high throughput,and flexibility.However,errors in accuracy and repeatability,which arise from a variety of sources such as mechani...Industrial robots are integral to modern manufacturing systems,enabling high precision,high throughput,and flexibility.However,errors in accuracy and repeatability,which arise from a variety of sources such as mechanical wear,calibration issues,and environmental factors,can significantly impact the performance of industrial robots.This paper aims to explore the theoretical modeling of errors in industrial robot systems and propose compensation strategies to enhance their accuracy and repeatability.Key factors contributing to errors,such as kinematic,dynamic,and environmental influences,are discussed in detail.Additionally,the paper explores various compensation techniques,including geometric error compensation,dynamic compensation,and adaptive control approaches.Through the integration of error modeling and compensation methods,industrial robots can achieve improved performance,ensuring higher operational efficiency and product quality.The paper concludes by highlighting the challenges and future research directions for improving the accuracy and repeatability of industrial robots in practical applications.展开更多
Contour error is the deviation between the actual displacement and reference trajectory,which is directly related to the machining accuracy.Contour error compensation poses substantial challenges because of the time-v...Contour error is the deviation between the actual displacement and reference trajectory,which is directly related to the machining accuracy.Contour error compensation poses substantial challenges because of the time-varying,nonlinear,and strongly coupled characteristics of parallel machining modules.In addition,the time delay in the system reduces the timeliness of the feedback data,thereby making online contour error calculations and compensation particularly difficult.To solve this problem,the generation mechanism of the time delay of the feedback data and contour error is revealed,and a systematic method for the identification of the time-delay parameter based on Beckhoff’s tracking error calculation mechanism is proposed.The temporal alignment between the position commands and feedback data enables the online calculation of the contour error.On this basis,the tracking error of the drive axes(an important factor resulting in end-effector contour errors)is used for the contour error calculation.Considering the ambiguous parameter-setting logic of the servo drive,the servo parameter is calculated in reverse using the steady-state error to obtain the tracking error model of the drive axes.Furthermore,combined with the system time-delay model,an online correction method for the tracking error estimation model is established.To achieve an accurate mapping of the drive-axis tracking error and end-effector contour error,a bounded iterative search method for the nearest contour point and online calculation model for the contour error are respectively established.Finally,an online compensation controller for contour error is designed.Its effectiveness is verified by a machining experiment on a frame workpiece.The machining results show that the contour error reduces from 68μm to 45μm,and the finish machining accuracy increases by 34%.This study provides a feasible method for online compensation of contour error in a system with time delay.展开更多
This study aimed to identify and compensate for the geometric errors of the double swiveling axes in a five-axis computer numerical control(CNC)machining center.Hence,a three-dimensional coordinate calculation algorit...This study aimed to identify and compensate for the geometric errors of the double swiveling axes in a five-axis computer numerical control(CNC)machining center.Hence,a three-dimensional coordinate calculation algorithm for a measured point with additional rotational rigid body motion constraints is proposed.The motion constraints of the rotational rigid body were analyzed,and a mathematical model of the measured point algorithm in the swiveling axes was established.The Levenberg-Marquard method was used to solve the nonlinear superstatically determined equations.The spatial coordinate error was used to separate the spatial deviation of the measured point.An identification model of the position-independent and position-dependent geometric errors was established.The three-dimensional coordinate-solving algorithm of the measured point in the swiveling axis and geometric error identification method based on the Monte Carlo method were analyzed numerically.Geometric error measurement and cutting experiments were performed on a VMC25100U five-axis machining center,which integrated two swiveling axes.Geometric errors of the A-and B-axes were identified and measured experimentally.The angular positioning errors before and after compensation were measured using a laser interferometer,which verified the effectiveness of the proposed algorithm.A cutting experiment of a round table part was performed.The shape and position accuracy of the processed part before and after compensation were detected using a coordinate measuring machine.It verified that the geometric error of the swiveling axis was effectively compensated by the algorithm proposed herein.展开更多
Null compensation interferometry is the primary testing method for the manufacture of ultra-high-precision aspheric mirrors.The crosstalk fringes generated by stray light in interferometry can affect accuracy and pote...Null compensation interferometry is the primary testing method for the manufacture of ultra-high-precision aspheric mirrors.The crosstalk fringes generated by stray light in interferometry can affect accuracy and potentially prevent the testing from proceeding normally.Position errors include the decenter error,tilt error,and distance error.During the testing process,position errors will impact the testing accuracy and the crosstalk fringes generated by stray light.To determine the specific impact of position errors,we use the concept of Hindle shell testing of a convex aspheric mirror,and propose the simulation method of crosstalk fringes in null compensation interferometry.We also propose evaluation indices of crosstalk fringes in interferometry and simulate the influence of position errors on the crosstalk fringes.This work aims to help improve the design of compensation interferometry schemes,enhance the feasibility of the design,reduce engineering risks,and improve efficiency.展开更多
The process of ground vehicle dynamic gravimetry is inevitably affected by the carrier’s maneuvering acceleration,which makes the result contain a large amount of dynamic error.In this paper,we propose a dynamic erro...The process of ground vehicle dynamic gravimetry is inevitably affected by the carrier’s maneuvering acceleration,which makes the result contain a large amount of dynamic error.In this paper,we propose a dynamic error suppression method of gravimetry based on the high-precision acquisition of external velocity for compensating the horizontal error of the inertial plat-form.On the basis of platform gravity measurement,firstly,the dynamic performance of the system is enhanced by optimizing the horizontal damping network of the inertial platform and selecting its parameter.Secondly,an improved federal Kalman filtering algorithm and a fault diagnosis method are designed using strapdown inertial navigation system(SINS),odometer(OD),and laser Doppler velocimeter(LDV).Simulation validates that these methods can improve the accuracy and robustness of the external velocity acquisition.Three survey lines are selected in Tianjin,China,for the gravimetry experiments with different maneuvering levels,and the results demonstrate that after dynamic error suppression,the internal coincidence accuracies of smooth and uniform operation,obvious acceleration and deceleration operation,and high-dynamic operation are improved by 70.2%,73.6%,and 77.9%to reach 0.81 mGal,1.30 mGal,and 1.94 mGal,respectively,and the external coinci-dence accuracies during smooth and uniform operation are improved by 48.6%up to 1.66 mGal.It is shown that the pro-posed method can effectively suppress the dynamic error,and that the accuracy improvement increases with carrier maneuver-ability.However,the amount of residual error that can not be entirely eliminated increases as well,so the ground vehicle dynamic gravimetry should be maintained in the carrier for smooth and uniform operation.展开更多
A new method was proposed, in which a high-power CO2 laser modulated by high frequency was used as the driv- ing source to heat up a surface-temperature sensor. The continual beam and the pulsed beam sent out by the s...A new method was proposed, in which a high-power CO2 laser modulated by high frequency was used as the driv- ing source to heat up a surface-temperature sensor. The continual beam and the pulsed beam sent out by the same laser could be used in the same system to carry on the static calibration of the radiation thermometer and the dynamic calibration of the temperature sensor to be checked. The frequency-response characteristics of high-speed radiation thermometer surpassed that of the temperature sensor, therefore it could be used as the reference value to calibrate the latter and let system error be cor- rected. Differences in the environment of the sensor installing and the error caused by the change of thermo-physical proper- ty could be avoided. Thus, the difficult problem of traceable dynamic calibration of temperature was solved. In experiment, to obtain the frequency characteristics of the thermocouple and the dynamic performance of the K type thermocouple, which could compensate the dynamic characteristics of the sensor, the sensor was dynamically corrected by using the method, and then the mathematical model was established.展开更多
In this paper we address the dynamics of compensation cutting process from both Laplace s frequency domain and the time domain of the first time, using the two computer aided analyzing softwares: MATLAB and SIMULI...In this paper we address the dynamics of compensation cutting process from both Laplace s frequency domain and the time domain of the first time, using the two computer aided analyzing softwares: MATLAB and SIMULINK. Theoretical analysis and simulation experiments firstly show that not only the systematical stiffness of workpiece, spindle and tools, but also the regenerated coefficient affects the compensation displacement effect. The results show that the SREC is practicable in reality to decease the spindle induced errors in many engineering applications such as hard boring through simulation and the preliminary experiment results.展开更多
One of the important trends in precision machining is the development ofreal-time error compensation technique. The error compensation for multi-axis CNC machine tools isvery difficult and attractive. The modeling for...One of the important trends in precision machining is the development ofreal-time error compensation technique. The error compensation for multi-axis CNC machine tools isvery difficult and attractive. The modeling for the geometric error of five-axis CNC machine toolsbased on multi-body systems is proposed. And the key technique of the compensation―identifyinggeometric error parameters―is developed. The simulation of cutting workpiece to verify the modelingbased on the multi-body systems is also considered.展开更多
Low weight and good toughness thin plate parts are widely used in modem industry, but its flexibility seriously impacts the machinability. Plenty of studies locus on the influence of machine tool and cutting tool on t...Low weight and good toughness thin plate parts are widely used in modem industry, but its flexibility seriously impacts the machinability. Plenty of studies locus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surfacc errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling fbrces calculated by the micro-unit cutting force model arc loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed mcthod not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.展开更多
Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining qualit...Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.展开更多
In order to improve the navigation accuracy of an inertial navigation system （INS）, composed of quartz gyroscopes, the existing real-time compensation methods for periodic errors in quartz gyroscope drift and the pe...In order to improve the navigation accuracy of an inertial navigation system （INS）, composed of quartz gyroscopes, the existing real-time compensation methods for periodic errors in quartz gyroscope drift and the periodic error term relationship between sampled original data and smoothed data are reviewed. On the base of the results, a new compensation method called using former period characteristics to compensate latter smoothness data （UFCL for short） method is proposed considering the INS working characteristics. This new method uses the original data without smoothing to work out an error conversion formula at the INS initial alignment time and then compensate the smoothed data errors by way of the formula at the navigation time. Both theoretical analysis and experimental results demonstrate that this method is able to cut down on computational time and raise the accuracy which makes it a better real-time compensation approach for periodic error terms of quartz micro electronic mechanical system （MEMS） gyroscope＇s zero drift.展开更多
Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixtur...Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.展开更多
Reduction of error due to the influence of temperature on the quartz flexible accelerometer without any heating device is a difficult task, and is also a tendency for research and application. In this paper, static an...Reduction of error due to the influence of temperature on the quartz flexible accelerometer without any heating device is a difficult task, and is also a tendency for research and application. In this paper, static and dynamic temperature compensation models are established in order to reduce the temperature influence on accelerometer measurement accuracy. Combined with the experiment data, the relationship between the accelerometer output accuracy, temperature and the magnitude of acceleration is analyzed. The data collected from the temperature experiment show that output value of the accelerometer varies with temperature. The method of uniaxial quadrature experiment is adopted and the accelerometer output value is gauged at temperature ranging from-20℃ to 50℃. Having used the static and the dynamic temperature compensation models, the accelerometer temperature error compensation experiment is conducted and the compensated errors by the two models are analyzed. The result shows that the compensated value meets the technical requirements. Two technical indicators, the zero bias K0 and the scaling factor K1, which are used to measure the degree of accelerometers, are both improved and their fluctuation ranges are reduced.展开更多
Existing errors in the structure and kinematic parameters of multi-legged walking robots,the motion trajectory of robot will diverge from the ideal sports requirements in movement.Since the existing error compensation...Existing errors in the structure and kinematic parameters of multi-legged walking robots,the motion trajectory of robot will diverge from the ideal sports requirements in movement.Since the existing error compensation is usually used for control compensation of manipulator arm,the error compensation of multi-legged robots has seldom been explored.In order to reduce the kinematic error of robots,a motion error compensation method based on the feedforward for multi-legged mobile robots is proposed to improve motion precision of a mobile robot.The locus error of a robot body is measured,when robot moves along a given track.Error of driven joint variables is obtained by error calculation model in terms of the locus error of robot body.Error value is used to compensate driven joint variables and modify control model of robot,which can drive the robots following control model modified.The model of the relation between robot＇s locus errors and kinematic variables errors is set up to achieve the kinematic error compensation.On the basis of the inverse kinematics of a multi-legged walking robot,the relation between error of the motion trajectory and driven joint variables of robots is discussed.Moreover,the equation set is obtained,which expresses relation among error of driven joint variables,structure parameters and error of robot＇s locus.Take MiniQuad as an example,when the robot MiniQuad moves following beeline tread,motion error compensation is studied.The actual locus errors of the robot body are measured before and after compensation in the test.According to the test,variations of the actual coordinate value of the robot centroid in x-direction and z-direction are reduced more than one time.The kinematic errors of robot body are reduced effectively by the use of the motion error compensation method based on the feedforward.展开更多
Due to the characteristics of high efficiency,wide working range,and high flexibility,industrial robots are being increasingly used in the industries of automotive,machining,electrical and electronic,rubber and plasti...Due to the characteristics of high efficiency,wide working range,and high flexibility,industrial robots are being increasingly used in the industries of automotive,machining,electrical and electronic,rubber and plastics,aerospace,food,etc.Whereas the low positioning accuracy,resulted from the serial configuration of industrial robots,has limited their further developments and applications in the field of high requirements for machining accuracy,e.g.,aircraft assembly.In this paper,a neural-network-based approach is proposed to improve the robots’positioning accuracy.Firstly,the neural network,optimized by a genetic particle swarm algorithm,is constructed to model and predict the positioning errors of an industrial robot.Next,the predicted errors are utilized to realize the compensation of the target points at the robot’s workspace.Finally,a series of experiments of the KUKA KR 500–3 industrial robot with no-load and drilling scenarios are implemented to validate the proposed method.The experimental results show that the positioning errors of the robot are reduced from 1.529 mm to 0.344 mm and from 1.879 mm to 0.227 mm for the no-load and drilling conditions,respectively,which means that the position accuracy of the robot is increased by 77.6%and 87.9%for the two experimental conditions,respectively.展开更多
Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll wor...Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll workpieces, and types of measurement systems and measurement methods have been developed. However, low measurement efficiency and low measurement accuracy caused by setting errors are the common disadvantages for surface profile measurement of microstructured roll workpieces. In order to shorten the measurement time and enhance the measurement accuracy, a method for self-calibration and compensation of setting errors is proposed for surface profile measurement of microstructured roll workpieces. A measurement system is constructed for the measurement, in which a precision spindle is employed to rotate the roll workpiece and an air-bearing displacement sensor with a micro-stylus probe is employed to scan the microstructured surface of the roll workpiece. The resolution of the displacement sensor is 0.14 nm and that of the rotary encoder of the spindle was 0.15r~. Geometrical and mathematical models are established for analyzing the influences of the setting errors of the roll workpiece and the displacement sensor with respect to the axis of the spindle, including the eccentric error of the roll workpiece, the offset error of the sensor axis and the zero point error of the sensor output. Measurement experiments are carded out on a roll workpiece on which periodic microstructures are a period of 133 i^m along the circumferential direction. Experimental results demonstrate the feasibility of the self-compensation method. The proposed method can be used to detect and compensate the setting errors without using any additional accurate artifact.展开更多
To improve the robustness of high-precision servo systems, quantitative feedback theory （QFT） which aims to achieve a desired robust design over a specified region of plant uncertainty is proposed. The robust design...To improve the robustness of high-precision servo systems, quantitative feedback theory （QFT） which aims to achieve a desired robust design over a specified region of plant uncertainty is proposed. The robust design problem can be solved using QFT but it fails to guarantee a high precision tracking. This problem is solved by a robust digital QFT control scheme based on zero phase error （ZPE） feed forward compensation. This scheme consists of two parts： a QFT controller in the closed-loop system and a ZPE feed-forward compensator. Digital QFT controller is designed to overcome the uncertainties in the system. Digital ZPE feed forward controller is used to improve the tracking precision. Simulation and real-time examples for flight simulator servo system indicate that this control scheme can guarantee both high robust performance and high position tracking precision.展开更多
Simulated star maps serve as convenient inputs for the test of a star sensor, whose standardability mostly depends on the centroid precision of the simulated star image, so it is necessary to accomplish systematic err...Simulated star maps serve as convenient inputs for the test of a star sensor, whose standardability mostly depends on the centroid precision of the simulated star image, so it is necessary to accomplish systematic error compensation for the simple Gaussian PSF（or SPSF, in which PSF denotes point spread function）. Firstly, the error mechanism of the SPSF is described, the reason of centroid deviations of the simulated star images based on SPSF lies in the unreasonable sampling positions（the centers of the covered pixels） of the Gaussian probability density function. Then in reference to the IPSF simulated star image spots regarded as ideal ones, and by means of normalization and numerical fitting, the pixel center offset function expressions are got, so the systematic centroid error compensation can be executed simply by substituting the pixel central position with the offset position in the SPSF. Finally, the centroid precision tests are conducted for the three big error cases of Gaussian radius r = 0.5, 0.6, 0.671 pixel, and the centroid accuracy with the compensated SPSF（when r = 0.5） is improved to 2.83 times that of the primitive SPSF, reaching a 0.008 pixel error, an equivalent level of the IPSF. Besides its simplicity, the compensated SPSF further increases both the shape similarity and the centroid precision of simulated star images, which helps to improve the image quality and the standardability of the outputs of an electronic star map simulator（ESS）.展开更多
Due to large workspace,heavy-duty and over-constrained mechanism,a small deformation is caused and the precision of the 2-DOF planar parallel manipulator is affected.The kinematic calibration cannot compensate the end...Due to large workspace,heavy-duty and over-constrained mechanism,a small deformation is caused and the precision of the 2-DOF planar parallel manipulator is affected.The kinematic calibration cannot compensate the end-effector errors caused by the small deformation.This paper presents a method combined step kinematic calibration and linear forecast real-time error compensation in order to enhance the precision of a two degree-of-freedom(DOF) planar parallel manipulator of a hybrid machine tool.In the step kinematic calibration phase of the method,the end-effector errors caused by the errors of major constant geometrical parameters is compensated.The step kinematic calibration is based on the minimal linear combinations(MLCs) of the error parameters.All simple and feasible measurements in practice are given,and identification analysis of the set of the MLCs for each measurement is carried out.According to identification analysis results,both measurement costs and observability are considered,and a step calibration including step measurement,step identification and step error compensation is determined.The linear forecast real-time error compensation is used to compensate the end-effector errors caused by other parameters after the step kinematic calibration.Taking the advantages of the step kinematic calibration and the linear forecast real-time error compensation,a method for improving the precision of the 2-DOF planar parallel manipulator is developed.Experiment results show that the proposed method is robust and effective,so that the position errors are kept to the same order of the measurement noise.The presented method is attractive for the 2-DOF planar parallel manipulator and can be also applied to other parallel manipulators with fewer than six DOFs.展开更多
文摘Thermal errors in CNC machine tools,particularly those involving the spindle,significantly affect machining accuracy and performance.These errors,caused by temperature fluctuations in the spindle and surrounding components,result in dimensional deviations that can lead to poor part quality and reduced precision in high-speed manufacturing processes.This paper explores thermal error modeling and compensation methods for the spindle of five-axis CNC machine tools.A detailed analysis of the heat generation,transfer mechanisms,and finite element analysis(FEA)is presented to develop accurate thermal error models.Compensation techniques,such as model-based methods,sensor-based methods,real-time compensation algorithms,and hybrid approaches,are critically reviewed.This study also discusses the challenges in real-time compensation and the integration of thermal error compensation with machine tool control systems.The objective is to provide a comprehensive understanding of thermal error phenomena and their compensation strategies,ultimately contributing to the enhancement of machining accuracy in advanced manufacturing applications.
文摘Industrial robots are integral to modern manufacturing systems,enabling high precision,high throughput,and flexibility.However,errors in accuracy and repeatability,which arise from a variety of sources such as mechanical wear,calibration issues,and environmental factors,can significantly impact the performance of industrial robots.This paper aims to explore the theoretical modeling of errors in industrial robot systems and propose compensation strategies to enhance their accuracy and repeatability.Key factors contributing to errors,such as kinematic,dynamic,and environmental influences,are discussed in detail.Additionally,the paper explores various compensation techniques,including geometric error compensation,dynamic compensation,and adaptive control approaches.Through the integration of error modeling and compensation methods,industrial robots can achieve improved performance,ensuring higher operational efficiency and product quality.The paper concludes by highlighting the challenges and future research directions for improving the accuracy and repeatability of industrial robots in practical applications.
基金Supported by National Natural Science Foundation of China(Grant Nos.52375018,92148301).
文摘Contour error is the deviation between the actual displacement and reference trajectory,which is directly related to the machining accuracy.Contour error compensation poses substantial challenges because of the time-varying,nonlinear,and strongly coupled characteristics of parallel machining modules.In addition,the time delay in the system reduces the timeliness of the feedback data,thereby making online contour error calculations and compensation particularly difficult.To solve this problem,the generation mechanism of the time delay of the feedback data and contour error is revealed,and a systematic method for the identification of the time-delay parameter based on Beckhoff’s tracking error calculation mechanism is proposed.The temporal alignment between the position commands and feedback data enables the online calculation of the contour error.On this basis,the tracking error of the drive axes(an important factor resulting in end-effector contour errors)is used for the contour error calculation.Considering the ambiguous parameter-setting logic of the servo drive,the servo parameter is calculated in reverse using the steady-state error to obtain the tracking error model of the drive axes.Furthermore,combined with the system time-delay model,an online correction method for the tracking error estimation model is established.To achieve an accurate mapping of the drive-axis tracking error and end-effector contour error,a bounded iterative search method for the nearest contour point and online calculation model for the contour error are respectively established.Finally,an online compensation controller for contour error is designed.Its effectiveness is verified by a machining experiment on a frame workpiece.The machining results show that the contour error reduces from 68μm to 45μm,and the finish machining accuracy increases by 34%.This study provides a feasible method for online compensation of contour error in a system with time delay.
基金Supported by Shanxi Provincial Natural Science Foundation(Grant No.2021JM010)The Youth Innovation Team of Shaanxi Universities.
文摘This study aimed to identify and compensate for the geometric errors of the double swiveling axes in a five-axis computer numerical control(CNC)machining center.Hence,a three-dimensional coordinate calculation algorithm for a measured point with additional rotational rigid body motion constraints is proposed.The motion constraints of the rotational rigid body were analyzed,and a mathematical model of the measured point algorithm in the swiveling axes was established.The Levenberg-Marquard method was used to solve the nonlinear superstatically determined equations.The spatial coordinate error was used to separate the spatial deviation of the measured point.An identification model of the position-independent and position-dependent geometric errors was established.The three-dimensional coordinate-solving algorithm of the measured point in the swiveling axis and geometric error identification method based on the Monte Carlo method were analyzed numerically.Geometric error measurement and cutting experiments were performed on a VMC25100U five-axis machining center,which integrated two swiveling axes.Geometric errors of the A-and B-axes were identified and measured experimentally.The angular positioning errors before and after compensation were measured using a laser interferometer,which verified the effectiveness of the proposed algorithm.A cutting experiment of a round table part was performed.The shape and position accuracy of the processed part before and after compensation were detected using a coordinate measuring machine.It verified that the geometric error of the swiveling axis was effectively compensated by the algorithm proposed herein.
基金the National Key Research and Development Program of China(2022YFB3403404)the Youth Innovation Promotion Association,CAS(2022213)the National Natural Science Foundation of China(62127901 and 62305334).
文摘Null compensation interferometry is the primary testing method for the manufacture of ultra-high-precision aspheric mirrors.The crosstalk fringes generated by stray light in interferometry can affect accuracy and potentially prevent the testing from proceeding normally.Position errors include the decenter error,tilt error,and distance error.During the testing process,position errors will impact the testing accuracy and the crosstalk fringes generated by stray light.To determine the specific impact of position errors,we use the concept of Hindle shell testing of a convex aspheric mirror,and propose the simulation method of crosstalk fringes in null compensation interferometry.We also propose evaluation indices of crosstalk fringes in interferometry and simulate the influence of position errors on the crosstalk fringes.This work aims to help improve the design of compensation interferometry schemes,enhance the feasibility of the design,reduce engineering risks,and improve efficiency.
基金supported by the Shanxi Provincial Natural Science Basic Research Program Young Talent Project(S2019-JC-QN-2408).
文摘The process of ground vehicle dynamic gravimetry is inevitably affected by the carrier’s maneuvering acceleration,which makes the result contain a large amount of dynamic error.In this paper,we propose a dynamic error suppression method of gravimetry based on the high-precision acquisition of external velocity for compensating the horizontal error of the inertial plat-form.On the basis of platform gravity measurement,firstly,the dynamic performance of the system is enhanced by optimizing the horizontal damping network of the inertial platform and selecting its parameter.Secondly,an improved federal Kalman filtering algorithm and a fault diagnosis method are designed using strapdown inertial navigation system(SINS),odometer(OD),and laser Doppler velocimeter(LDV).Simulation validates that these methods can improve the accuracy and robustness of the external velocity acquisition.Three survey lines are selected in Tianjin,China,for the gravimetry experiments with different maneuvering levels,and the results demonstrate that after dynamic error suppression,the internal coincidence accuracies of smooth and uniform operation,obvious acceleration and deceleration operation,and high-dynamic operation are improved by 70.2%,73.6%,and 77.9%to reach 0.81 mGal,1.30 mGal,and 1.94 mGal,respectively,and the external coinci-dence accuracies during smooth and uniform operation are improved by 48.6%up to 1.66 mGal.It is shown that the pro-posed method can effectively suppress the dynamic error,and that the accuracy improvement increases with carrier maneuver-ability.However,the amount of residual error that can not be entirely eliminated increases as well,so the ground vehicle dynamic gravimetry should be maintained in the carrier for smooth and uniform operation.
基金Research Project Supported by Shanxi Scholarship Council of China(No.2012-068)Taiyuan Science and Technology Agency(No.120247-20)Surface-temperature Sensor Dynamic Measurement and Calibration Technology Research of National Defense Fundamental Scientific Research
文摘A new method was proposed, in which a high-power CO2 laser modulated by high frequency was used as the driv- ing source to heat up a surface-temperature sensor. The continual beam and the pulsed beam sent out by the same laser could be used in the same system to carry on the static calibration of the radiation thermometer and the dynamic calibration of the temperature sensor to be checked. The frequency-response characteristics of high-speed radiation thermometer surpassed that of the temperature sensor, therefore it could be used as the reference value to calibrate the latter and let system error be cor- rected. Differences in the environment of the sensor installing and the error caused by the change of thermo-physical proper- ty could be avoided. Thus, the difficult problem of traceable dynamic calibration of temperature was solved. In experiment, to obtain the frequency characteristics of the thermocouple and the dynamic performance of the K type thermocouple, which could compensate the dynamic characteristics of the sensor, the sensor was dynamically corrected by using the method, and then the mathematical model was established.
文摘In this paper we address the dynamics of compensation cutting process from both Laplace s frequency domain and the time domain of the first time, using the two computer aided analyzing softwares: MATLAB and SIMULINK. Theoretical analysis and simulation experiments firstly show that not only the systematical stiffness of workpiece, spindle and tools, but also the regenerated coefficient affects the compensation displacement effect. The results show that the SREC is practicable in reality to decease the spindle induced errors in many engineering applications such as hard boring through simulation and the preliminary experiment results.
基金This project is supported by National Natural Science Foundation of China (No.E059905019)
文摘One of the important trends in precision machining is the development ofreal-time error compensation technique. The error compensation for multi-axis CNC machine tools isvery difficult and attractive. The modeling for the geometric error of five-axis CNC machine toolsbased on multi-body systems is proposed. And the key technique of the compensation―identifyinggeometric error parameters―is developed. The simulation of cutting workpiece to verify the modelingbased on the multi-body systems is also considered.
基金Supported by National Natural Science Foundation of China(Grant No.51175304)Shandong Provincial Science and Technology Development Plan of China(Grant No.2013GHZ30305)
文摘Low weight and good toughness thin plate parts are widely used in modem industry, but its flexibility seriously impacts the machinability. Plenty of studies locus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surfacc errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling fbrces calculated by the micro-unit cutting force model arc loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed mcthod not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.
基金supported by the National Natural Science Foundation of China(Nos.52005413,52022082)Natural Science Basic Research Plan in Shaanxi Province of China(No.2021JM-054)the Fundamental Research Funds for the Central Universities(No.D5000220135)。
文摘Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.
基金New Century Program for Excellent Telents (NCET- 04-0162)National Defense Basic Research Program (K1204060116)
文摘In order to improve the navigation accuracy of an inertial navigation system （INS）, composed of quartz gyroscopes, the existing real-time compensation methods for periodic errors in quartz gyroscope drift and the periodic error term relationship between sampled original data and smoothed data are reviewed. On the base of the results, a new compensation method called using former period characteristics to compensate latter smoothness data （UFCL for short） method is proposed considering the INS working characteristics. This new method uses the original data without smoothing to work out an error conversion formula at the INS initial alignment time and then compensate the smoothed data errors by way of the formula at the navigation time. Both theoretical analysis and experimental results demonstrate that this method is able to cut down on computational time and raise the accuracy which makes it a better real-time compensation approach for periodic error terms of quartz micro electronic mechanical system （MEMS） gyroscope＇s zero drift.
基金supported by National Natural Science Foundation of China (Grant No. 50975200)National Key Technologies R & D Programmer of China (Grant No. 2009ZX04014-021)
文摘Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.
基金supported by the Importation and Development of High-caliber Talents Project of Beijing Municipal Institutions(No.IT&TCD201304115)
文摘Reduction of error due to the influence of temperature on the quartz flexible accelerometer without any heating device is a difficult task, and is also a tendency for research and application. In this paper, static and dynamic temperature compensation models are established in order to reduce the temperature influence on accelerometer measurement accuracy. Combined with the experiment data, the relationship between the accelerometer output accuracy, temperature and the magnitude of acceleration is analyzed. The data collected from the temperature experiment show that output value of the accelerometer varies with temperature. The method of uniaxial quadrature experiment is adopted and the accelerometer output value is gauged at temperature ranging from-20℃ to 50℃. Having used the static and the dynamic temperature compensation models, the accelerometer temperature error compensation experiment is conducted and the compensated errors by the two models are analyzed. The result shows that the compensated value meets the technical requirements. Two technical indicators, the zero bias K0 and the scaling factor K1, which are used to measure the degree of accelerometers, are both improved and their fluctuation ranges are reduced.
基金supported by National Natural Science Foundation of China (Grant Nos. 50675079,50875246)Program for Innovative Research Team (in Science and Technology) in University of Henan Province,China
文摘Existing errors in the structure and kinematic parameters of multi-legged walking robots,the motion trajectory of robot will diverge from the ideal sports requirements in movement.Since the existing error compensation is usually used for control compensation of manipulator arm,the error compensation of multi-legged robots has seldom been explored.In order to reduce the kinematic error of robots,a motion error compensation method based on the feedforward for multi-legged mobile robots is proposed to improve motion precision of a mobile robot.The locus error of a robot body is measured,when robot moves along a given track.Error of driven joint variables is obtained by error calculation model in terms of the locus error of robot body.Error value is used to compensate driven joint variables and modify control model of robot,which can drive the robots following control model modified.The model of the relation between robot＇s locus errors and kinematic variables errors is set up to achieve the kinematic error compensation.On the basis of the inverse kinematics of a multi-legged walking robot,the relation between error of the motion trajectory and driven joint variables of robots is discussed.Moreover,the equation set is obtained,which expresses relation among error of driven joint variables,structure parameters and error of robot＇s locus.Take MiniQuad as an example,when the robot MiniQuad moves following beeline tread,motion error compensation is studied.The actual locus errors of the robot body are measured before and after compensation in the test.According to the test,variations of the actual coordinate value of the robot centroid in x-direction and z-direction are reduced more than one time.The kinematic errors of robot body are reduced effectively by the use of the motion error compensation method based on the feedforward.
基金co-supported by the Natural Science Foundation of Jiangsu Province(No.BK20190417)the National Natural Science Foundation of China(No.52005254)the National Key R&D Program of China(No.2018YFB1306800)。
文摘Due to the characteristics of high efficiency,wide working range,and high flexibility,industrial robots are being increasingly used in the industries of automotive,machining,electrical and electronic,rubber and plastics,aerospace,food,etc.Whereas the low positioning accuracy,resulted from the serial configuration of industrial robots,has limited their further developments and applications in the field of high requirements for machining accuracy,e.g.,aircraft assembly.In this paper,a neural-network-based approach is proposed to improve the robots’positioning accuracy.Firstly,the neural network,optimized by a genetic particle swarm algorithm,is constructed to model and predict the positioning errors of an industrial robot.Next,the predicted errors are utilized to realize the compensation of the target points at the robot’s workspace.Finally,a series of experiments of the KUKA KR 500–3 industrial robot with no-load and drilling scenarios are implemented to validate the proposed method.The experimental results show that the positioning errors of the robot are reduced from 1.529 mm to 0.344 mm and from 1.879 mm to 0.227 mm for the no-load and drilling conditions,respectively,which means that the position accuracy of the robot is increased by 77.6%and 87.9%for the two experimental conditions,respectively.
文摘Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll workpieces, and types of measurement systems and measurement methods have been developed. However, low measurement efficiency and low measurement accuracy caused by setting errors are the common disadvantages for surface profile measurement of microstructured roll workpieces. In order to shorten the measurement time and enhance the measurement accuracy, a method for self-calibration and compensation of setting errors is proposed for surface profile measurement of microstructured roll workpieces. A measurement system is constructed for the measurement, in which a precision spindle is employed to rotate the roll workpiece and an air-bearing displacement sensor with a micro-stylus probe is employed to scan the microstructured surface of the roll workpiece. The resolution of the displacement sensor is 0.14 nm and that of the rotary encoder of the spindle was 0.15r~. Geometrical and mathematical models are established for analyzing the influences of the setting errors of the roll workpiece and the displacement sensor with respect to the axis of the spindle, including the eccentric error of the roll workpiece, the offset error of the sensor axis and the zero point error of the sensor output. Measurement experiments are carded out on a roll workpiece on which periodic microstructures are a period of 133 i^m along the circumferential direction. Experimental results demonstrate the feasibility of the self-compensation method. The proposed method can be used to detect and compensate the setting errors without using any additional accurate artifact.
基金This project was supported by the Aeronautics Foundation of China (00E51022).
文摘To improve the robustness of high-precision servo systems, quantitative feedback theory （QFT） which aims to achieve a desired robust design over a specified region of plant uncertainty is proposed. The robust design problem can be solved using QFT but it fails to guarantee a high precision tracking. This problem is solved by a robust digital QFT control scheme based on zero phase error （ZPE） feed forward compensation. This scheme consists of two parts： a QFT controller in the closed-loop system and a ZPE feed-forward compensator. Digital QFT controller is designed to overcome the uncertainties in the system. Digital ZPE feed forward controller is used to improve the tracking precision. Simulation and real-time examples for flight simulator servo system indicate that this control scheme can guarantee both high robust performance and high position tracking precision.
文摘Simulated star maps serve as convenient inputs for the test of a star sensor, whose standardability mostly depends on the centroid precision of the simulated star image, so it is necessary to accomplish systematic error compensation for the simple Gaussian PSF（or SPSF, in which PSF denotes point spread function）. Firstly, the error mechanism of the SPSF is described, the reason of centroid deviations of the simulated star images based on SPSF lies in the unreasonable sampling positions（the centers of the covered pixels） of the Gaussian probability density function. Then in reference to the IPSF simulated star image spots regarded as ideal ones, and by means of normalization and numerical fitting, the pixel center offset function expressions are got, so the systematic centroid error compensation can be executed simply by substituting the pixel central position with the offset position in the SPSF. Finally, the centroid precision tests are conducted for the three big error cases of Gaussian radius r = 0.5, 0.6, 0.671 pixel, and the centroid accuracy with the compensated SPSF（when r = 0.5） is improved to 2.83 times that of the primitive SPSF, reaching a 0.008 pixel error, an equivalent level of the IPSF. Besides its simplicity, the compensated SPSF further increases both the shape similarity and the centroid precision of simulated star images, which helps to improve the image quality and the standardability of the outputs of an electronic star map simulator（ESS）.
基金supported by National Natural Science Foundation of China(Grant No. 50805140)National Hi-tech Research and Development Program of China(863 Program,Grant No. 2007AA04Z227)
文摘Due to large workspace,heavy-duty and over-constrained mechanism,a small deformation is caused and the precision of the 2-DOF planar parallel manipulator is affected.The kinematic calibration cannot compensate the end-effector errors caused by the small deformation.This paper presents a method combined step kinematic calibration and linear forecast real-time error compensation in order to enhance the precision of a two degree-of-freedom(DOF) planar parallel manipulator of a hybrid machine tool.In the step kinematic calibration phase of the method,the end-effector errors caused by the errors of major constant geometrical parameters is compensated.The step kinematic calibration is based on the minimal linear combinations(MLCs) of the error parameters.All simple and feasible measurements in practice are given,and identification analysis of the set of the MLCs for each measurement is carried out.According to identification analysis results,both measurement costs and observability are considered,and a step calibration including step measurement,step identification and step error compensation is determined.The linear forecast real-time error compensation is used to compensate the end-effector errors caused by other parameters after the step kinematic calibration.Taking the advantages of the step kinematic calibration and the linear forecast real-time error compensation,a method for improving the precision of the 2-DOF planar parallel manipulator is developed.Experiment results show that the proposed method is robust and effective,so that the position errors are kept to the same order of the measurement noise.The presented method is attractive for the 2-DOF planar parallel manipulator and can be also applied to other parallel manipulators with fewer than six DOFs.
