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NCMS CTMA Symposium Detroit 11:30 am Wednesday, April 1, 2009 Jim Dallam MAG Cincinnati Tel: +1 859 534 4619
VALMT Volumetric Accuracy for Large Machine Tools Date: 01-APR-2009 1
Date: 01-APR-2009
Project Objective
Establish a new method to improve the Volumetric Accuracy for Large Machine Tools (VALMT) via a collaborative project during the eighteen months from January 2008 to July 2009.
Date: 01-APR-2009
Different Machines Present a Different Kinematic Axis Stack-Up from Part to Tool
MAG U5-1500
- Part - Base - Linear X - Linear Y - Linear Z - Rotary C - Rotary A - Spindle/Tool
MAG H5-1000
- Part - Rotary B - Linear Z - Base - Linear X - Linear Y - Rotary A - Spindle/Tool
FOGS SU-16
- Part - Rotary W - Base - Linear X - Linear Y - Linear Z - Rotary C - Rotary A - Spindle/Tool
VALMT Volumetric Accuracy for Large Machine Tools
Date: 01-APR-2009
Project Tasks
Advance software previously developed to a production ready commercial product available for use on large five-axis machines equipped with the Siemens 840D controller. Test the calibration and compensation methods using path positioning and cutting tests. Investigate the feasibility and complexity of a black-box solution that could be retrofit to legacy machine tools.
Date: 01-APR-2009
Project Partners
Date: 01-APR-2009
Beam Lock
Date: 01-APR-2009
Small size, portable, large measurable volume Super long-term dimensional and thermal stability Typical accuracy 5 -10 times better than machine accuracy requirement AT fully autonomous control with 8 hour battery Unlimited AZ and 140 deg EL Pivot accuracy better than 5 microns
VALMT Volumetric Accuracy for Large Machine Tools Date: 01-APR-2009 8
Beam Lock
Point Cloud T3 Laser Tracker The approach consists of a laser tracker and spindle-mounted active target. The tracker and active target interact to maintain a metrology beam-lock as the machine tool is positioned to a cloud of points within its work envelope. For each point, the actual location (as determined by the metrology) is contrasted with the commanded (desired) location to develop the point compensation values. Software automation then determines the volumetric compensations using a polynomial-equation-based, kinematic-error-model of the machine, and transfers them into the machine tool controller. After this calibration, when the production machine is commanded to a desired location, the volumetric compensations are automatically applied during the move to improve the path and actual location.
VALMT Volumetric Accuracy for Large Machine Tools Date: 01-APR-2009 9
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The VALMT project utilizes Sinumeriks Open Architecture Compile Cycle technology. This integrates the polynomial-equation-based, kinematic-error-model into the real-time CNC path control algorithms. Siemens CNC Base System
Date: 01-APR-2009
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Siemens Sinumerik 840D Open Architecture CNC with VALMT Compile Cycle
The compile cycle computes the volumetric compensations at the interpolation level of the CNC. When the controller calculates the path trajectory, it breaks the motion block into discrete points evenly spaced in time that are then fed into the servo loop of each axis. Below we see a typical acceleration, constant velocity, deceleration, and stop characteristic of a move. Each of these points is fed into the VALMT compile cycle algorithm for compensation. Each time slice is treated as a pose of the machine, and compensations are computed for all of the servo commands for that time slice to correct machine location and orientation. The algorithm takes about 100us to execute, well within the real time constraints of the system.
Distance
Time
VALMT Volumetric Accuracy for Large Machine Tools Date: 01-APR-2009 12
MAG is a leading large machine tool builder with a global service and maintenance organization
FTV??
Applications
Heads, Blocks Cams, Cranks Transmissions Chassis Composite Panels Engine Components
Titanium Components Aluminum Components Composite Structures Engines Components Landing Gear
Thin Film Solar Panels Gear Case Assemblies Hubs Planetary Carriers Bearings Shafts, Blades
MAG will commercialize this volumetric compensation methodology in parallel with API.
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Instrument used
1D Laser + Optics 6D Laser + Optics 1D Laser Tracer + Cats eye
Rotary Axes Measurement limitations time N/A or 2-4 days separate test N/A or separate test N/A or separate test N/A or separate test 1-2 days < 4 hours 1-2 days depends on grid density
Verification method
Measure diagonals
3-D Grid VALMT polynomial equation solution for all positions and poses
3 Axes
Measure diagonals At any arbitrary positions and poses in the work space
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Machine 1
80 70 Number of Points Number of Points 60 50 40 30 20 10 0 Better Accuracy 80 70 Number of Points Number of Points 60 50 40 30 20 10 0 Better Accuracy W orse Accuracy W orse Accuracy 80 70 80 70
Machine 2
100 80 Number of Points
Machine 3
Before
60
40
20
After
Number of Points
60
80
60
40
20
All machines showed volumetric compensation improved static positioning accuracy. All machines could be compensated to better than three times the process repeatability.
VALMT Volumetric Accuracy for Large Machine Tools Date: 01-APR-2009 16
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Follow-up Points-of-Contact
The National Center for Manufacturing Science Ann Arbor, MI Tony Haynes, tel: 734 995 4930 Boeing Research & Technology St. Louis, MO Phil Freeman, tel: +1 314 234 4050 Automated Precision, Inc. Rockville, MD Dave Maxham, tel: +1 240 268 0400 MAG Cincinnati Hebron, KY Jim Dallam, tel: +1 859 534 4619 Siemens Energy and Automation, Inc. Mason, OH Roger Hart, tel: +1 513 218 1626
Date: 01-APR-2009
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