WORKPIECE MEASUREMENTS ON NC(CNC)-MACHINE TOOLS: MACHINE CONFIGURATIONS/ APPLICATION EXAMPLES T. Pfeifer and A. Fiirst Department of Metrology, Laboratory of Machin e Tool, R WTH Aachen, F. R. G.
Abstract. The adaption of a 3-D probe system to numeri c ally controlled machine tools enables a measurement of workpiece in machining positions. By measurements before, during and after machining, errors can either be eliminated or recognized well in advance. The selection and adaption of a suitable 3-D probe will be described. The necessary extension of the machine control unit as well as application examples and limitations will also be explained. Keywords. Metropogy, process control, NC(CNC)-machine tools, 3-D probe. 1. INTRODUCTION Due to their flexibility, numerically
immediate vicinity of the machining
controlled machine tools are being
process itself. Then, only such a
increasingly applied in small and
quality control can help to avoid dead
medium scale series trolling the
times between o ccurance and recognition of machining errors and consequently
relative movement be-
tween workpiece dire~t
production. Con-
and tool either by
reduce costs due to waste
pieces or
remachining.A direct check of geometri e s
or indirect measuring systems
leaves little room for geometric
on the machine tool itself guarantee s
deviations. However, other production
short dead times. One possibility for
process parameters non-specific to
realizing direct quality control is to
the machine - for ego fixtures for
use an electronic 3-D probe in
workpiece and tool - lead to geometric
connection with the measuring system
deviations that could far exceed the
of the machine tool. This system
positioning uncertainty of the ma-
substitutes the tool and probes the
chine in an unloaded state. Since the
workpiece just as in case of coordinate
influence of such
measuring machines /1/ (Fig.1). The
disturbing
quantities cannot be predetermined,
modification of the Ne-unit necessary
it is essential to integrate a con-
for this purpose, the choice and
stant or intermittent control of
adapt ion of a suitable 3-D probe as
machined geometries within the pro-
well as the application possibilities
duction process. This control is more
and limitations will be discussed
efficient if conducted in the
below.
279
T. Pfeifer and A. Ftirst
280
also done in the extended control unit.
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3. SELECTION AND ADAPTION OF A
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3-D probes are already known from their
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from probes with integrated measruing systems (measuring 3-D probes) and
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switchable 3-D probes with integrated micro-switches (touch trigger 3-D probes)
(Fig. 2) /3/. The choice of
Fig. 1. Intermittend Workpiece Measurement on CNC-Machine Tool
2. SYSTEM CONFIGURATION The function of an NC-machine is to be extended with respect to measuring a workpiece clamped on the machine by replacing the tool by an electronic 3-D probe. After connecting the probe signals with the machine's position feedback unit the machine can be used as a coordinate measuring device. The coordinate system of the machine tool together with the position feedback
cv
Parallelogram of Plate Springs
0lnducti~e
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a..ring Points' Micro · Switches
Displacement Pick.Ups
Zeiss
Renisl\lw
unit and 3-D probe form the basis of a spatial reference system for a 3-D determination of discrete probing pOints on the workpiece. In order to
Fig. 2. Principles of Measuring and Touch Trigger 3-D Probes
acquire the necessary accuracy of the reference system a correction of the
one of these systems must be made with
systematic positioning error in space
special respect to an application on
of the unloaded machine is essential.
machine tools. Since the probe is to
~his
1s done by registering the in-
be changed like a tool, the following
dividual position errors with com-
case-specific selection criteria are
parison measuring systems - ego Laser
first to be consiJered:
Interferometer /2/ - and storing them
- place of use
in form of a correction matrix in an
- maximum stylus overtravel
extended
- signal decoupling possibilities
CNC unit. Processing the
correction matrix as well as the conversion of the probing coordinates to geometric elements of the workpiece are
- vibratory sensitivity Due to their mechanical structure
281
Workpiece measurements on NC(CNC)-machine tools
- mostly orthogonal oriented parallelo-
ainty of touch trigger systems is larger
grams of plate springs or one spring
than that of measuring systems, it is
membrane - measuring probe systems
yet sufficient for our purpose /3/.
have certain limitations as compared
The cost price is less due to the simple
with touch trigger probe systems with
structure. On the whole, touch trigger
regard to the place of use an<1. maximum
3-D probes are to be preferred for
stylus overtravel. When adapting the
applications on machine tools.
probe to machine tools with horizontal
shows such a
working spindles, the weight of the
tool holder of a NC-boring/milling
Figure 3
3-D probe adapted to the
stylus causes various stylus pretavel according to the stylus geumetry. The
Wireless Irff1smissiGn
01 Probe Sign!1
necessary range of stylus overtravel
~~~~r.- RfCtiving Coil
of 10 mm (brake path of machine tool in rapid traverse) for protecting the
Transmitting Coil
probe against desstruction cannot be easily observed due to the restricted deforming capability of the spring
Triggering J - 0 Probe
elements. From the view-point of automatic probe changing from a tool magazine, a faultless decoupling of the probe signal - by wireless transmission, for example - is essential. As compared with the transmission of the impulse of a touch trigger probe,
Fig. 3. Adaption of a 3-D Probe to the
the transmission of analogous values
Tool holder of a NC-Machine
of a measuring probe requires more
Tool
elaborate electronic circuitry. machine.
As mentioned previously, the
Due to the relatively small pretravel
faultless decoupling of the probe sig-
until the impulse triggerring (see
nal is an important aspect when adapt-
chap. 5), touch trigger probes can be adjusted with relatively high pre-
ing a 3-D probe system to an automatic tool (probe) changer. Basically, sig-
tensions or spring constants which
nal transmission can be done via con-
improves their stability against
tacts or by wireless coupling.
vibrations. The same measures of
mission via contacts is subject to'
c~using
an improvement of the
vibratory sensitivity are not possible using a measuring probe since higher
Trans-
disturbances because of wear and pollution so that wireless transmission wins preference.
Using touch trigger
spring constants easily lead to
Frobes involves affordable electronic
measuring errors resulting from various bending deviations of the
efforts for wireless transmission. One alternative for signal transmis-
stylus /3/.
sion will be illustrated by examples
~part
from the selection criteria
already
described, the measuring un-
shown in Fig. 3 and 4.
Inductive decoupling is done via two coils.
The transmitting coil is ad-
certainty and buying costs are also to
justed onto the changeable probe and
be considered. Investigations show
the receiving coil is mounted on the
that although the measuring uncert-
s~indle
I.C.- L
box.
Figure 4 shows the
T. Pfeifer and A. Furst
282
Control - Control Addition " is discribed. This configuration is necessary for actual process intermittent workpiece measurements with a feedback of measuring results to avoid errors. However, less extended system stages are possible; the coupling of the 3-D probe system enables certain measuring tasks to be integrated within the machining process. In the lowest version the probe signal is used to reset the machine's position feedback unit at Fig. 4. Wireless Transmission of
the probed point (Fig. 5) or to inter-
Probe Signal by Detuning of
rupt machining by an alarm. This zero
Resonant Circuit
pOint can, for example, be used as a reference point to compensate deviation
transmitting and receiving circuit.
between workpiece and machine
The function is based on detunins a
coordinate system due to thermal effects
resonant circuit whose inductance is
or to detect clamping errors of work-
determined by the loosely coupled
piece. The possibility to interrupt the
receiver coil.
By opening one of
process is an interesting application
the switches or deflecting the probe
case for fully-automated processes as,
stylus a resonance shift is caused,
for example, intended for future DNC-
which in turn leads to a voltage drop
system/4,5/. The probe acts as an aid
at the output end of the transformer.
to detect clamping errors or to check
This voltage drop is detected by a
production errors caused by tool
highly selective synchronous demodu-
damage or wear. A simplified quality control by checking complete ma-
lation circuitry.
After rectification,
aaaption ana debouncing, a trigger
chining is ?ossible. If the 3-D probe
impulse is generated to read and
is adjusted on the machine table, it
store data of the machine's position
is possible to conduct an automatic
feedback unit.
langitudinal or radius
Besides the rela-
compensation
tively simple and therefore fair
of tool. A pre-adjustment of the tool
priced set-uf, the following features
is then superfluous. In the next
characterize the transmission system: - signal transmission without auxiliary energy on transmitting end - insensitivity to stray fields - low time constants (50 JUS) - insensitivity to distance alternations (Fig.4, bottom) 4. NECESSARY USE-SPECIFIC
version the probe system is directly connected to the position feedback unit. On probing, the measuring values are read-off and displayed. Thus the machine operator is able to re-adjust the workpiece or make alterations in machining program, when testing the NC-progam at the first part of a batch. Furthermore,
EXTENSIONS OF THE MACHINE
with the aid of a step-gauge, one can
CONTROL
conduct a periodic check of
Within the introduction the system
positioning accuracy of machine tool
configuration "Machine Tool - 3-D Probe
(ref. chap. 5) with relative ease.
Workpiece measurements on NC(CNC)-machine tools
283
Measuring procedures on the machine
Other possibilities for processing
tool described till now can be
measuring
considerably improved with regard to
control unit by additional measuring
reliability and speed, if, in an-
data exist in extending the control
other stage, measuring values are
unit by additional measuring modules.
processed with the aid of an
In future this can be realized in a
data exist in extending the
additional data processing unit . Only
multiprocessor control structure
then can a true 3-D workpiece
whose concept enhances modularity
measurement
realized. The data processing unit is
by virtue of uniform interfaces and a c ommon data way / 6 / . A combination
to compute geometric elements out of
of the last two alternatives yields
on the machine be
probed points and determine
a third for elaborate measuring tasks,
differences between nominal and
The extended control could be useo
actual values. This task can be fulfilled on a separat distant small-
for storing individual probed points
scale computer - ego desk calculator
instructions for such operations
or mini-computer - or on a central
have been masked and interpreted.
process computer in case of inter-
Further processing is done on a
in a storage module after special NC
linked NC-machines. Besides quality
seperate computer after transmitting
control protocols, it may be
the data via a suitable communication
necessary to have a direct feedback
medium.
of data to the machine to correct the
is advantageous since the instruction
NC-program. This can, for example, be
set of the control unit does not
done using a BTR - interface between machine tool control and compute.r.
Such a system configuration
require to be considerably extended It suffices
for measuring tasks.
to have additional instructions for
8
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5. APPLICATION EXAMPLES AND LIMITATIONS At our laboratory detailed investi-
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qat ions are beinq conducted reqarding the applications and limitations of process intermittent workpiece measurements on a development system "3-D Probe - NC-boring/milling machine and Process Computer". The most im-
Fig. 5. Possibilities of Using a 3-D Probe on NC-Machine Tools
portant aspect of the investigation are the influence of machine errors and special measuring conditions
T. Pfeifer and A. FUrst
284
during machining. On the one hand it
also varies with the direction of
is important to determine the random errors that cannot be compensated.
approach of the probe /3/. The most
On the other the systematic errors
stylus is deflected over one contact
and their compensation must also be
or bearing pOint(Fig. 2) and the
investigated.
disconnecting sequence of the other
The random errors consist of
measurements (Fig. 6 B) .
inconvenient values arise when the
two contacts changes during repeated positioning dispersion of the un-
- Both, the repeatability and
loaded machine and the measuring
difference between pretravels in-
uncertainty of the probe system to-
crease with larger lengths of the
gether with its fixture errors. Both
stylus.
error components will be explained by
In the example illustrated,both
analysing experimental results. Con-
components when probing accross the
sidering the probe system, the
probe axis
following errors of a triggering
worst case, superimposite to a total
system (Fig. 2) are possible:
error of
- According to the direction of
±
er~or
(xy -plane) can, in the 4.5;um. A convenient
adjustment - eg., the line =45 0 ,225 0
approach of the probe different
corresponds to the x-axis of
pretravel or switching distances are
machining/measuring center - and a
necessary to issue a touch trigger
calibration of probe ball along
impulse by opening the switching
several positions in the xy plane
contacts (Fig. 6 A) This gives rise
leads to a considerable reduction of
to a measuring error principally
this value /7/. Furthermor e , if the
systematic in nature, but difficult
probing is done along axes (x,y,z),
to compensate under operating
the measuring error can be reduced
conditions /7/. This error is there-
to approx.
fore listed as a random one that
investigations, the errors are
±
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independant of the probing speed which, in fact is particularly advantageous for curtailing measuring ToUC.hltlgVtlOCtty : v - lOO mnv'mln Slyru~ lrnglh : TS "20mm
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mid-point of the probe ball lies without the axis of the tool/probe
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- and the probe system does not undergo a rotary shift relative to this
Fig. 6. Measuring uncertainty of a Touch Trigger 3-D Probe cannot be compensated. - Due to varying contact
spindle position, then the maladjustment of the probe ball can be determined by an initial calibration cycle.
conditions,
the repeatability of measurements
In this case the adjustment error i s random in nature and is about as
285
Workpiece measurements on NC(CNC)-machine tools
large as the tool clamping error. The possibilities of avoidung the
as checked by probing a step-gauge with a touch trigger probe (dynamic
systematic clamping error are either
registration of measuring values) .
the establishment of a fixed relation
Although the results of checking the
between the radial spindle and probe
positioning error with a step-gauge
ball position or precise mechanical
contain random errors of both
construction of the probe that
machine tool and probe, the
guarantees a central position of the probe ball even when using various styli. Otherwise, when a fixed
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must be conducted after each change in order to compensate the error. In view of curtailing measuring times, this alternative is to be given last
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The random part of the positioning error is considerably dependant on the back-lash between machine tables and drives as well as the stability
Fig. 7. Inspection of Position Accuracy of a NC-Machine Tool with Step-Gauge and 3-D Pobe
of the position control loop. Since,
in Comparison to Inspection
in the case of using direct position
with a Laser-Inferferometer
feedback units like scales, the drive elements have littel influence on the
positioning dispersion is
lost motion, the lost motion and
comparatively lower. Besides it must
positioning dispersion are not large.
be mentioned that the positioning
Using a touch trigger 3-D probe
dispersion in the example of this
measurements are done by dynamic
machine tool is relatively low and
probing. In this case the measuring
hence convenient for improvement of
results are not influenced by in-
the measuring accuracy by compensating
stabilities of the position control
the systematic positioning error. This
loop. The functions within a measuring
is shown in the upper part of Fig. 8,
cycle of a position control loop
where the mean positioning error of
consist of positioning the probe ball
both measurement procedures and the
between probed points, stopping within
mean remaining error after online
the probe's overtravel limits and
error compensation is drawn. The
reversing direction of approach for
remaining positioning error amounts
the next point to be probed. This is
about + 1 um and lies within the limits
vivid from the error curve of an NC-
of the positioning dispersion.
boring/milling machine with a medium operating scale (Fig. 7). The lower
Among possible systematic errors of
part of the figure depcits the random
direct workpiece measurements on the
positioning error as measured with a
machine tool the following may be
laser interferometer (registration of
considered: displacements of the
a measuring values in still state) or
reference coordinate system due to
T. Pfeifer and A. FUrst
286
thermal effects, alternations of the
-The displacements (Llx, Ll y, Ll z) occur
reference length of the scales due to thermal effects and the systematic
almost instantaneously with tem-
positioning deviation. As compared
increases in length up to 60;um. A
with measuring machines, large
vertical temperature gradient (y-axis)
thermal errors of machine tools
along the cross section causes
can result from varying
bending, that leads to translational displacements along the y-axis of
perature changes. The spindle box
temperatures of the operating environment, heating of machine tool
upto 35 ?m. Only slight displcace-
caused by friction in the drive elements
ments in the x-axis are observed
and gears as well as heating from the
since the temperature gradi e nt ill the
cutting process itself. Figure a shows
horizontal direction is quickly stabilized. -On cooling (spindle revolutions n=o) the displacements reduce almost instantaneously with the temperature -Even after long warming-up times, load changes cause displacements upto
10 fm.
On the one hand this example shows that intermittent probing of reference edges on a workpiece or on the machine table during machining can compensate thermal displacements by resetting the Fig. a.Spatial Displacement of Cutter Spindle of a Boring / Milling Machine caused by Heating of Spindlebox
machine's position feedback unit. On the other hand it also shows the limitations of measuring on the machine due to long measuring cycles. For example, when measuring during the
the thermal displacements of the
cooling period of machine tool for a
spindle box of a milling machine by
time of 20 min displacements up to
varying the spindle revolutions in the
10
~
(Fig. 7,left) are possible. Even
still state. The temperatures of the
in this case a compensation during
drive chassis at a characteristic
measuring is possible by reference
point are also to be seen in the
pOint probing. This is demonstrated
figure.
The displacements are measured on the example where a workpiece is
continually at the tool clamping position with a measuring 3-D probe.
machined and then measured on the came
This
machine. The workpiece is of aluminium
enables the direct measurement of dis-
with equidistant stagad holes that are bored in sequence. Figure 9A shows the
placements in space relative to the machine's coordinate system. The results indicate the following: -After a cold start, the temperature of the spindle box rises up to 20 0 K and does not reach a stable value even after 2 hours.
machining sequence. After machining each stage, a reference point on the workpiece is probed, and the displacement due to thermal influence registered is compensated by shifting the reference pOint in the Ne-program. Inspite of long warming-up times, a
Workpiece measurements on NC(CNC)-ma chine tools
287
thermal displacement of approx. 20jUm
results with respect to the dispersion of
was measured between machining of the first and last boring stages. Results
the hole mid-pOints. Thus it is concluded that roundness-errors of the tool ~pindle
of measurements on a high preciSion
causing form errors of the holes in-
coordinate measuring machine confirmed
fluence the measuring results to a
that these displacements could be
greater extent.
Furthermore, it is
largely eliminated by integrating the
shown tha t thermal influences are
measuring cycle within the machining
largel y compensated so in the cooling
sequence (Fig.9B). The standard
rhase.
The compensation is done by
probing reference pOints after measurAI
ing a complete bored stage.
For probing
of 20 points a measuring time of ap[,rox. 81
S U tI (la,d 0 •• • 11 , 011
During this 2 , 5 min was re~uired. rel ative l y short int erval there was no
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considerable tem perature changes and conse~uently
only slight thermal dis-
placements arose.
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Fig. 9.Measurement of Bored Holes on
by intermittent probing of reference points during machining and also by
the NC-Machining/Measuring
measuring a finished workpiece.
Center in Comparison to Mea-
Practically the question arises, as to
surement on a Coordinate Mea-
how often probing is to be done or
suring Machine
what rest error is tolerable without increasing measuring times and con-
deviation of mid-pOint coordinates
sequently production times too. A
between successive boring stages(same
decision is to be taken by considering
z-nominal position) amounted to a
the error and the ensuing costs due to it.
;urn'
maximal of 3 Without compensation, the displacements would have caused
of various thermal elongations of
even greater standard deviations. The
workpiece and scale of position feed-
rest dispersions of mid-pOint coordinates are mainly due to roundness
able geometric deviations during ma-
errors of the holes (max. 4
chining or cause measuring errors when
~m)
that
Compensation is more difficult in case
back unit. This can lead to consider-
strongly influence the results of de-
measuring the finished workpiece. An
terminating the geometry of holes by
illustration is given in Fig.9C. The
.measurement of discrete pOints /8/.
curve shows the mean position deviation
A comparison between results of mea-
of the hole mid-pOint with reference to
surements on a coordinate measuring
the axis of the first concentric hole.
machine and on a tool machining/mea-
Considering the results obtained on a
suring center confirms this. Inspite
coordinate measuring machine shows a
of larger random errors of the
rise in negative deviations in pro-
machining/measuring center, there is
portion with the distance of concen-
no significant difference of measuring
tric holes from the reference hole.
288
T. Pfeifer and A. FUrst
This error-characteristic indicates a difference between workpiece and scale temperatures durinq machininq. This is also clear from results of measurements with the machining/measuring center. A difference between both
- The thermal elongations must first be compensated since they are often larger or in fact contrary to the positioning error. - The amount of the positioning error must be estimated for each machine
measurements exists only between the
tool. Should it be less than the
first two hole mid-points. It amounts
error to be expected from other in-
to approx. 4
fID
which lies within
the range of the mean positioning error of this machine (Fig. 7). The relatively good agreement
of the
measuring results was achieved after
fluencing quantities, then no compensation is necessary. - The measuring devices for determining the positioning error must be available; mathematical methods
an online compensation of temperature
for
differences between measuring scale
developed.
and workpiece by means of additional
processing errors are to be
- Since the reference coordinate
temperature measurements. However,
system is subject to wear and there-
compensation of temperature differ-
fore not permanently stable,
ences during machining and during
correction values must be constantly
measuring is e ve n possible without
updated by periodic machine checks
temperature measurements when a known
(eg. checking with a step-gauge).
reference scale is probed in certain intervals. For example, a reference length made of
invar and mounted on
the machine table can be periodically probed. Such a reference length is considered to be thermically stable because of its low extension coefficient. In an integrated machining or measuring cycle, first the reference length and then a particular machined length of the workpiece will be probed at regular intervals. The longitudinal change of the measuring scale results from a difference of the measured value with respect to a value at a reference temperature (T=293k). Thus it is possible to measure changes in length relative to the workpiece. Finally, the following aspects are to be considered when examining the systematix positioning error in space: - Basically, the systematic positioning
The first three points must be anaylsed with regard to a particular application case and will not be discussed here. One dimensional positioning errors such as lost motion pitch error of lead screw or indexing errors on measuring scales can, today, be corrected by controls available to the user. However, the determination, description and compensation of errors with a more complex characertistic or such that superimpose each other is more difficult. In this connection one dimensional errors with short periods, straightness and squareness are to be mentioned.
deviations
Figure 8 (upper
part) shows the curves of a positioning error resulting from a long period due to deviation from straightness and a short period error of the measuring system with a periodic length
oUt, =635;urn and an amplitude of 2/'UIT\. An accurate analysis of this error is
error is to be compensated if it is
only possible by continuous trans-
at least twice as large as the random
mission error measurement/11/. The
error.
mathematical description can be done
Workpiece measurements on NC(CNC)-machine tools
with the aid of a polynome and periodic function. A similar description was used for online error compensation, when measuring a step-gauge on machine
289
description and consequently that of the compensation is dependant on the density of measuring lines which in turn must be adjusted to a praticular machine tool.
tool (Fig 7).
6. CONCLUSION The fundament for connecting measurable error components to the spatial
Adapting a 3-D probe system to a machine
positioning error is the measurement
tool enables a reduction of production
on a network within the machine's
uncertainties. Depending on the com-
operating area /7/. Each measuring line
plexity of the measuring tasks, the
is related to the reference pOint of
machine's control system is to be
the machine's position feedback units.
extended. Controls with modular
The actual coordinate system of the
structures and unified interfaces are
machine is determined from measurements
particularly suitable for the integration of additional functions. In
of the deviation in straightness and squareness in the direction of traverse. order to achieve measuring accuracy, the random error of the unloaded maResults of one-dimensional error meachine and the 3-D probe must be small
surements are connected to this coordinate system. The position
as compared to the machining error.
deviations in any point are calculated
Systematic machining errors such as
from a linear interpolation between
thermal displacements of the coordinate
the deviations along the measuring
system and geometric errors of machine
lines/7,10/. The quality of error
slideways can be compensated.
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