Self-calibration has the potential of: 1) removing the dependence on any external pose sensing information; 2) producing high accuracy measurement data over the entire workspace of the system with an extremely fast measurement rate; 3) being automated and completely noninvasive; 4) facilitating on-line accuracy compensation; and 5) being cost effective. A general framework is introduced in this paper for the self-calibration of parallel manipulators. The concept of creating forward and inverse measurement residuals by exploring conflicting information provided with redundant sensing is proposed. Some of these ideas have been widely used for robot calibration when robot end-effector poses are available. By this treatment, many existing kinematic parameter estimation techniques can be applied for the self-calibration of parallel mechanisms. It is illustrated through a case study, i.e. calibration of the Stewart platform, that with this framework the design of a suitable self-calibration system and the formulation of the relevant mathematical model become more systematic. A few principles important to the system self-calibration are also demonstrated through the case study. It is shown that by installing a number of redundant sensors on the Stewart platform, the system is able to perform self-calibration. The approach provides a tool for rapid and autonomous calibration of the parallel mechanism.

Self-calibration of parallel mechanisms with a case study on Stewart platforms

Real-time compensation of time-variant volumetric error on a machining center.

An error compensation system has been developed to enhance the time-variant volumetric accuracy of a 3-axis machining center by correcting the existing machine errors through sensing, metrology, and computer control techniques. A general methodology has been developed to synthesize both the geometric and thermal errors of machines into a time-variant volumetric error model. Instead of the well-known 21 geometric error components, 32 machine linkage errors are formulated as a 4D error field including the space domain and the time domain. Different types of models are proposed for different kinds of thermal error components. A compen­ sation controller based on an IBM/PC has been linked with a CNC controller to compensate for machine errors in real time. This scheme has been implemented on a horizontal machining center and has been shown, using metrology instruments, to improve the machine accuracy by an order of magnitude. A cut workpiece in­ spected using a coordinate measuring machine (CMM) has also shown that di­ mension errors have been reduced from 92.4 fim to 18.9 \x,m in a dimension of 404 x 310 mm2 and the depth difference of milled surf aces has been reduced from 196 fim to 8 fim.

Real-time Compensation for Time-variant Volumetric Errors on a Machining Center

Purpose – The purpose of this research is to extend the previous approach to software error compensation to fused deposition modeling (FDM) machines and explores the approach to apply compensation by correcting slice files.Design/methodology/approach – In addition to applying the stereolithography (STL) file‐based compensation method from earlier research; a new approach using the slice file format to apply compensation is presented. Under this approach, the confounded effects of all errors in a FDM machine are mapped into a “virtual” parametric machine error model. A 3D artifact is built on the FDM machine and differences between its actual and nominal dimensions are used to estimate the coefficients of the error functions. A slice file compensation method is developed and tested on two types of parts as a means for further improving the error compensation for feature form error improvement. STL file compensation is also applied to a specific FDM 3000 machine and the results are compared with those of a ...

Error compensation for fused deposition modeling (FDM) machine by correcting slice files

The present study aims to establish a new compensation method for geometry errors of five-axis machine tools. In the kinematic coordinate translation of five-axis machine tools, the tool orientation is determined by the motion position of machine rotation axes, whereas the tool tip position is determined by both machine linear axes and rotation axes together. Furthermore, as a nonlinear relationship exists between the workpiece coordinates and the machine axes coordinates, errors in the workpiece coordinate system are not directly related to those of the machine axes coordinate system. Consequently, the present study develops a new compensation method, the decouple method, for geometry errors of five-axis machine tools. The method proposed is based on a model that considers the tool orientation error only related to motion of machine rotation axes, and it further calculates the error compensations for rotation axes and linear axes separately, in contrast to the conventional method of calculating them simultaneously, i.e. determines the compensation of machine rotation axes first, and then calculates the compensation associated with the machine linear axes. Finally, the compensation mechanism is applied in the postprocessor of a CAM system and the effectiveness of error compensation is evaluated in real machine cutting using compensated NC code. In comparison with previous methods, the present compensation method has attributes of being simple, straightforward and without any singularity point in the model. The results indicate that the accuracy of positioning was improved by a factor of 8–10. Hence, the new compensation mechanism proposed in this study can effectively compensate geometry errors of five-axis machine tools.

C.R. Liu

Papers

A Contribution to the Analysis and Compensation of the Geometric Error of a Machining Center