Kinematic modeling and error sensitivity analysis for on-machine five-axis laser scanning measurement under machine geometric errors and workpiece setup errors

Ibaraki, Soichi; Goto, Shunsuke; Tsuboi, Keisuke; Kojima, Noriaki

doi:10.1007/s00170-018-1874-4

Cited by 17 publications

(5 citation statements)

References 20 publications

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“…Nishikawa et al [10] indicate that the use of a laser sensor in a multi-axis machine yields quite similar results to the measurements of turbine blade sections obtained on a CMM. Ibaraki et al [4] also use a laser displacement sensor to measure different profiles on an axi-symmetrical part. To improve quality, they propose a kinematic model of the machine which brings out each contribution of various types of errors affecting the measurement with the aim of improving quality.…”

Section: Related Workmentioning

confidence: 99%

Optimal scanning strategy for on-machine inspection with laser-plane sensor

Phan

Quinsat

Lartigue

2019

Int J Adv Manuf Technol

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The purpose of this paper is to propose a scan path planning method for on-machine measurement (OMM) in a 5-axis machine-tool. Sensor accessibility can be enhanced using the 5 degrees of freedom and the spindle rotation. The laser-plane sensor replacing the cutting tool in the spindle enables to reduce the measurement time and thus allows for rapid decision-making concerning the geometrical conformity of manufactured parts and potential machining corrections. The scan path planning is based on the control of the overlap between two consecutive passes by managing the orientations and the coverage rate of laser beam. Therefore, both scanning quality and scanning time can be controlled by optimizing the overlap zones. In this paper, we adapt the method previously developed for 6-axis robots to a 5-axis machine-tool.

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Section: Related Workmentioning

confidence: 99%

Optimal scanning strategy for on-machine inspection with laser-plane sensor

Phan

Quinsat

Lartigue

2019

Int J Adv Manuf Technol

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“…Ibaraki et al [11] implemented the LDS on the spindle of a five-axis cradle machine tool and introduced an asynchronous calibration method for determining the beam direction and zero position of the sensor. The influence of the position and direction errors of the workpiece relative to the machine's rotation axis and the geometric error of the rotation axis on the measurement results were analyzed [12]. However, this method is not applicable to five-axis gantry machine tools.…”

Section: Introductionmentioning

confidence: 99%

A novel pose calibration method for laser displacement sensor in the five-axis on-machine measurement system

Wang,

Huang,

et al. 2024

J. Phys.: Conf. Ser.

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The five-axis on-machine measurement system, equipped with a laser displacement sensor, offers an effective approach for conducting on-site inspections of freeform surface parts. It is crucial to address the calibration error pertaining to the sensor’s pose, encompassing both the beam direction and the zero position, as it directly impacts the measurement accuracy. This paper presents a new approach for the calibration of a laser displacement sensor’s pose, which is mounted on the spindle of a five-axis gantry machine tool. The proposed method utilizes measurements taken from multiple angles of a standard ball. Through the utilization of spherical constraints and coordinate translation transformation, the Levenberg-Marquardt iteration method is employed to derive the sensor’s beam direction, while the least square method is used to determine the sensor’s zero position. Applying this proposed method, the maximum error in the distance between the centers of the standard double ball is below 0.008 mm, which can meet the precision requirements of on-site inspection of freeform surface parts.

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“…Their proposed model facilitates quantitative error estimation of task-specific measurement outcomes and paves the way for future error correction. Ibaraki et al further examined the geometric error modeling in an five-axis on-line measurement setup [65,66], achieved by integrating a laser displacement sensor into a vertical five-axis machine tool. By constructing an error prediction model that encompasses both the linear and rotary axes, they effectively assessed the influence of geometric errors on measured profiles, and provided a demonstration experiment on the profile measurement of an axis-symmetrical part.…”

Section: Introductionmentioning

confidence: 99%

Unified framework for geometric error compensation and shape-adaptive scanning in five-axis metrology systems

Zhang,

Yu,

Zhu

et al. 2024

Meas. Sci. Technol.

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In response to the escalating demand for precise shape metrology of complex optical surfaces, this study unveils a unified geometric error compensation and trajectory planning framework tailored for high-accuracy five-axis scanning metrology systems, which remains a notably underexplored field compared to error compensation in machine tools. Founded on a unified geometric model, the proposed framework seamlessly integrates a versatile shape-adaptive trajectory planning strategy, a thorough global error sensitivity analysis approach, and an exhaustive geometric error compensation scheme. Leveraging inverse kinematics, an innovative shape-adaptive scanning trajectory generation strategy is mathematically formulated, thereby facilitating adaptable measurement trajectory generation for diverse surface geometries. Employing forward kinematics, an exhaustive geometric error model is established to extensively address the 53 distinct geometric errors in the metrology system. This proposed error model fundamentally augments conventional geometric error models in machine tool by managing not only the geometric errors from the motion system, but also those from the probe and workpiece. To streamline the error compensation procedure, a novel global error sensitivity analysis approach is introduced, identifying both system-oriented and process-oriented sensitive geometric errors for targeted compensation. Experimental validation using a standard ball, which achieved an exceptional 89.35% reduction in the root mean square (RMS) of the measurement errors, further confirms the feasibility and effectiveness of the proposed framework. By offering an universal trajectory planning, sensitivity analysis and error compensation trinity for five-axis scanning metrology systems, this study sets the stage for precision advancements and design optimization across diverse configurations of metrology systems.

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Kinematic modeling and error sensitivity analysis for on-machine five-axis laser scanning measurement under machine geometric errors and workpiece setup errors

Cited by 17 publications

References 20 publications

Optimal scanning strategy for on-machine inspection with laser-plane sensor

Optimal scanning strategy for on-machine inspection with laser-plane sensor

A novel pose calibration method for laser displacement sensor in the five-axis on-machine measurement system

Unified framework for geometric error compensation and shape-adaptive scanning in five-axis metrology systems

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