Accuracy for Machines
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1 Accuracy for Machines Wolfram Meyer / AfM Technology GmbH Volumetric Compensation Process Etalon Forum 2013
2 Standard machine tool calibration partly by AfM Franchise partner AfM Portfolio Engineering Service Software Products MaCo Online Mathematics, memory and performence optimiced high portable source code, validated test data, onsite support Performance test of CMMs according to ISO and VDI 2617, error mapping, determination of residual errors for the VCMM Performance test of machine tool tools according to ISO 230 AfM Tools for volumetric compensation (not for sale) AfM Gauge-Check automated gauge measurement on ZEISS Calypso CMM s Accessories for LaserTARCER work world wide service for Volumetric compensation on machine tool tools The Quality Process Wizard (QPW) software for inspection process optimization base points and multi pins for LaserTracker
3 Standard machine tool calibration partly by AfM Franchise partner AfM Portfolio Engineering Service Software Produkte MaCo Online Mathematics, memory and performence optimiced high portable source code, validated test data, onsite support Performance test of CMMs according to ISO and VDI 2617, error mapping, determination of residual errors for the VCMM Performance test of machine tool tools according to ISO 230 AfM Tools for volumetric compensation (not for sale) AfM Gauge-Check automated gauge measurement on ZEISS Calypso CMM s Accessories for LaserTARCER work world wide service for Volumetric compensation on machine tool tools The Quality Process Wizard (QPW) software for inspection process optimization base points and multi pins for LaserTracker
4 Theme Volumetric compensation Experiencess of a international service provider
5 CNC controllers supported by AfM Option VCS (VCS A3 / VCS A5 / VCS A5plus / VCS Rotary) SINUMERIK 840D sl Option KinematicsComp / KinematicsOpt / HEIDENHAIN itnc 530 / HEIDENHAIN itnc 640 Option VAC / HMS HEC / FIDIA CXR / C10 / C20 / C40 Option FVC / FAGOR CNC 8070 / 8065 MAZAK Bosch Rexroth Option Volumetric Compensation / MATRIX 2 Option VCP / IndraMotion MTX Option 3D error compensation / 3D Rotary error compensation FANUC CNC / 15 / 15i / 30i / 31i
6 Vision What everybody wants
7 Vision What everybody wants
8 Vision What everybody wants
9 Vision What everybody wants
10 Experiences volumetric compensation
11 Experiences volumetric compensation have a lot of technical aspects Questions
12 Experiences volumetric compensation have a lot of technical aspects is not a book with seven seals Questions
13 Experiences volumetric compensation have a lot of technical aspects is not a book with seven seals could be handled Questions
14 Experiences volumetric compensation have a lot of technical aspects is not a book with seven seals could be handled is powerful Questions
15 Experiences volumetric compensation have a lot of technical aspects is not a book with seven seal could be handled is powerful will pay off Questions
16 Experiences volumetric compensation is complex
17 Experiences volumetric compensation is complex is a process Easier than that!
18 Experiences volumetric compensation is complex is a process is not a panacea Easier than that!
19 Experiences volumetric compensation is complex is a process is not a panacea is not by the way The wrong way Easier than that!
20 Experiences volumetric compensation is complex is a process is not a panacea is not by the way is not a standard The wrong way Easier than that!
21 Experiences volumetric compensation is complex is a process is not a panacea is not by the way is not a standard is not a question of measurement device Easier than that! The wrong way A wide range
22 The process volumetric compensation
23 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
24 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
25 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
26 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
27 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
28 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
29 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
30 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
31 The process CNC controller Bewertung machine tool verification volumetric compensation strategy error map fixtures calibration Precompensation
32 The customer is in focus controllersmanufacturer engineering, test & feedback machine tool builder consulting, training, analysis & assesssment Bosch Rexroth MAZAK End user machine user full service acceptance tests inspection tool manufacturer Product demo, service Customer training
33 Excample aircraft industry Retrofit Project Development compensation startegy Gantry axis / backlash calibration linear axis Volumetric calibration & verification linear axis backlash & position error calibration rotary axis Evaluation & Analysis Training course volumetric compensation
34 machine tool Compensated workspace: 13,9m³ X-Axis: 12000mm Y-Axis: 1625mm Z-Axis: 712mm machine tool with active position and backlash compensation
35 deviation [µm] gantry axis Z1 Position deviation and backlash z-axis (Master) 45,0 35,0 25,0 15,0 5,0-5,0-15,0 ztz Master Mechanic (+) ztz Master with CEC (+) ztz Master Mechanic (-) ztz Master with CEC (-) EZZ Master Mechanic (+) EZZ Master Mechanic (-) EZZ Master with CEC (+) EZZ Master with CEC (-) Backlash Mechanic Backlash with CEC Max 22,80 40,20 1,70 5,20-1,90-0,60 Min 0,30 21,80-0,30 0,60-22,40-4,20 Range 22,50 18,40 2,00 4,60 20,50 3,60
36 3D deviation Without Volumetric compensation Maximum 363 µm deviation With Volumetric compensation Maximum 40 µm deviation 3D deviation: The maximum volumetric deviation in the whole workspace of the machine tool
37 deviation [ ] A-Axis calibration Position deviation and backlash A-Axis 0,0300 0,0250 0,0200 0,0150 0,0100 0,0050 0,0000-0,0050-0,0100 ara Mechanic (+) ara with CEC (+) ara Mechanic (-) ara with CEC (-) [ ] EAA Mechanic (+) EAA Mechanic (-) EAA with CEC (+) EAA with CEC (-) Backlash Mechanic Backlash with CEC Max 0,0249 0,0255 0,0003 0,0004 0,0002 0,0003 Min 0,0000 0,0005-0,0005-0,0002-0,0020-0,0008 Range 0,0249 0,0250 0,0008 0,0006 0,0022 0,0011
38 Excample mold and die industry Project full error compensation of new machine tool Development compensation startegy for 43 error parameters (21 for X/Y/Z and 22 for A/C) Volumetric calibration & verification linear axis X/Y/Z component error compensation A/C-Achse location error compensation A/C-Achse Evaluation & Analysis, Presentation end customer
39 Results Verification with KinematicsComp on 5-axis gantry machine tool 160,0 140,0 120,0 100,0 80,0 60,0 40,0 20,0 0,0-20,0 Without Heidenhain Kinematics Comp With Heidenhain Kinematics Comp
40 3D deviation Without Volumetric compensation Maximum 159 µm deviation With Volumetric compensation Maximum 19 µm deviation 3D deviation: The maximum volumetric deviation in the whole workspace of the machine tool
41 11:40 13:10 14:40 16:10 17:40 19:10 20:40 22:10 23:40 1:10 2:40 4:10 5:40 7:10 8:40 10:10 11:40 13:10 14:40 16:10 17:40 19:10 20:40 22:10 23:40 1:10 2:40 4:10 5:40 7:10 8:40 10:10 11:40 13:10 14:40 16:10 17:40 19:10 20:40 22:10 23:40 1:10 2:40 4:10 5:40 7:10 8:40 10:10 11:40 13:10 14:40 Temperature conditions 29,0 [ C] 28,0 27,0 26,0 25,0 24,0 23,0 22,0 21,0 20,0 19,0 Calibration Verification linear axis Temperature over time Calibration Verification C-Axis Calibration Verification A-Axis Kinematic Opt for location errors 84,20 [ F] 83,20 82,20 81,20 80,20 79,20 78,20 77,20 76,20 75,20 74,20 73,20 72,20 71,20 70,20 69,20 68,20 67,20 66,20 X min [ C] X max [ C] Y [ C] Z in [ C] Z max [ C] Luft [ C] X min [ F] X max [ F] Y [ F] Z in [ F] Z max [ F] Luft [ F]
![Heidenhain KiComp KiComp Tracer absolut percentage Angular position [µrad] EAA 200,9](/docs-images/90/101411681/images/42-1.jpg "21,7 4,9-179,2-89% Axial motion [µm] EXA 21,9 15,5 1,8-6,3-29% Radial motions [µm] EYA")
![64,9 8,1 1,3-56,8-88% EZA 57,6 11,1 1,7-46,6-81% Tilt motions [µrad] EBA 53,3 27,2](/docs-images/90/101411681/images/42-2.jpg "2,8-26,1-49% ECA 60,8 21,8 2,2-39,0-64% Angular position [µrad] ECC 81,8 10,5")
![1,4-71,3-87% Axial motion [µm] EZC 5,0 5,2 0,3 0,2 4% Radial motions [µm] EXC 12,7 15,8](/docs-images/90/101411681/images/42-3.jpg "0,5 3,1 25% EYC 8,1 17,5 0,5 9,4 116% Tilt motions [µrad] EAC 10,7 15,9 0,8 5,2 49% EBC")
42 C-Axis A-Axis Komponentenabweichungen Rundachsen Axis Verification with Kinematics Comp on 5 axis gantry machine tool Without With U (max) Improvement Parameter Heidenhain Heidenhain KiComp KiComp Tracer absolut percentage Angular position [µrad] EAA 200,9 21,7 4,9-179,2-89% Axial motion [µm] EXA 21,9 15,5 1,8-6,3-29% Radial motions [µm] EYA 64,9 8,1 1,3-56,8-88% EZA 57,6 11,1 1,7-46,6-81% Tilt motions [µrad] EBA 53,3 27,2 2,8-26,1-49% ECA 60,8 21,8 2,2-39,0-64% Angular position [µrad] ECC 81,8 10,5 1,4-71,3-87% Axial motion [µm] EZC 5,0 5,2 0,3 0,2 4% Radial motions [µm] EXC 12,7 15,8 0,5 3,1 25% EYC 8,1 17,5 0,5 9,4 116% Tilt motions [µrad] EAC 10,7 15,9 0,8 5,2 49% EBC 15,1 18,2 0,9 3,1 20%
43 compensation of location errors of A/C-axes a-axis KinematicsOpt c-axis Measurement on machine tool
44 Thank you for your attention On our web pages you find this presentation in english and german language. Use that link for download. AfM Technology GmbH Gartenstraße Aalen Fon +49 (0) Fax: +49 (0) Wolfram Meyer / AfM Technology GmbH Volumetric Compensation Process Etalon Forum 2013
Accuracy for CMMs and Machine Tools
Systematic machine errors Rapid Calibration and Compensation of CMM and Machine ools: Recent Developments of the Lasertracer echnology Motivation Geometry errors he LaserRACER RAC-CAL for Error Mapping
Squareness C0Y A0Z B0Z
ETALON offers system solutions for highly accurate and complete geometric analysis, monitoring and accuracy improvement of machine tools, measuring machines, robots and structures. Innovative technologies
Dr. Heinrich Schwenke, CEO Etalon AG
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