Volumetric Accuracy for Large Machine Tools

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

The Continuing Challenge to Manufacture Interchangeable Parts

In the early 1800s before the Civil War, the challenge was to make military rifles with parts that could be swapped. After that war, the American System of Manufacture with precision interchangeable parts enabled making complex merchandise like sewing machines and typewriters. Today the challenge is to make the much larger parts for planes, ships, and tanks, to equal levels of repeatable precision. Laser interferometry methods are typically used to determine machine compensations. These methods improve machine accuracy, but require multiple setups by highly trained and experienced technicians, are time consuming, and account for significant lost revenue. A better method is needed.

VALMT Volumetric Accuracy for Large Machine Tools

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.

VALMT Volumetric Accuracy for Large Machine Tools

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.

VALMT Volumetric Accuracy for Large Machine Tools

Date: 01-APR-2009

Project Partners

The National Center for Manufacturing Science Ann Arbor, MI

Boeing Research & Technology St. Louis, MO Automated Precision, Inc. Rockville, MD MAG Cincinnati Hebron, KY Siemens Energy & Automation, Inc. Mason, OH Warner Robins Air Logistics Center Warner Robins, GA Naval Foundry & Propeller Center Philadelphia, PA Fleet Readiness Center East Cherry Point, NC Anniston Army Depot Anniston, AL

VALMT Volumetric Accuracy for Large Machine Tools

Date: 01-APR-2009

APIs T3 Laser Tracker and Active Target

Moving Active Target (AT)

Beam Lock

Stationary T3 Laser Tracker (with Pan & Tilt)

VALMT Volumetric Accuracy for Large Machine Tools

Date: 01-APR-2009

APIs T3 Laser Tracker and Active Target (AT)

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

Boeings Approach for Volumetric Error Compensation

Tool Axis Active Target

Short Tool Points Long Tool Points

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.
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Optimization and Real-Time Compensation Software

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Siemens Sinumerik 840D Open Architecture CNC

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

Siemens VCi Interface CC

VALMT Real Time Algorithms

VALMT Volumetric Accuracy for Large Machine Tools

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

Example path interpolation output from the CNC

Interpolation output with compensations from VALMT Compile Cycle.

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

Machines and equipment

FTV??

Applications

Heads, Blocks Cams, Cranks Transmissions Chassis Composite Panels Engine Components

Titanium Components Aluminum Components Composite Structures Engines Components Landing Gear

Large Frames Bearings Cases Planetary Carriers Lift Arms

Thin Film Solar Panels Gear Case Assemblies Hubs Planetary Carriers Bearings Shafts, Blades

Wheels, Axles, Brake Disks Chassis Components Engines and Transmissions

Pumps, Valves Compressors Molds Machinery Components Large Structures

MAG will commercialize this volumetric compensation methodology in parallel with API.

VALMT Volumetric Accuracy for Large Machine Tools

Date: 01-APR-2009

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Project Testing on Different 5-Axis Machines and Verification at Depot Sites

VALMT Volumetric Accuracy for Large Machine Tools

Date: 01-APR-2009

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Comparison of Error Mapping Technologies

Calibration method Sequential laser linear setups & measurements

Instrument used
1D Laser + Optics 6D Laser + Optics 1D Laser Tracer + Cats eye

Linear Axes limitations 3 Axes 3 Axes 3 Axes

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

Laser Tracker Laser Tracker + Active Target

3 Axes

Measure diagonals At any arbitrary positions and poses in the work space
Date: 01-APR-2009 15

Not limited, fully exercised <2 hours

VALMT Volumetric Accuracy for Large Machine Tools

Before and After Accuracy Graphs

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

60 50 40 30 20 10 0 Better Accuracy W orse Accuracy

Before

60

40

20

0 Better Accuracy 100 W orse Accuracy

After

50 40 30 20 10 0 Better Accuracy W orse Accuracy

Number of Points

60

80

60

40

20

0 Better Accuracy W orse Accuracy

All machines showed volumetric compensation improved static positioning accuracy. All machines could be compensated to better than three times the process repeatability.
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Advantages of This VALMT Approach

Complete Volumetric Calibration Measurements are taken within the full

volumetric work envelope of the machine combining serial kinematic errors and geometric effects not possible with current axis-by-axis methods.

Practical Metrology Methods Measurements are automated within a

single coordinate system using laser tracker technology that has proven to be a simple metrology tool that does not require extensive training to use.

Rapid Calibration Time Calibration is performed in a single setup with

automated measurement of hundreds of points completed in just a few hours compared to alternate methods that can take days or weeks.

Easy to Extend The model readily extends to arbitrary serial kinematic

structures, a key advantage over alternate methods.

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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

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