Case study / Retrofit / moving column machine tool
AfM - Accuracy for Machines
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 1
Volumetric Compensation
Volumetrische Vermessung
und Kompensation einer Heckert CS800
mit Heidenhain iTNC 530 und
Option KinematicsComp
Volumetric Calibration and Compensation
of a Heckert CS800 machine tool
with Heidenhain iTNC 530 and
Option KinematicsComp
Verbesserung der volumetrischen Genauigkeit um: 91% ≙ 248 µm
Improvement of volumetric accuracy by: 91% ≙ 248 µm
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 2
Zeitplan / Schedule
Vorarbeiten
Pre work
Montag
Monday
Steuerungsumrüstung der Heckert CS 800 auf HEIDENHAIN iTNC 530 / CNC Retrofit of
the Heckert CS 800 machine tool by using a modern HEIDENHAIN iTNC 530 CNC
Freischaltung der Option KinematicsComp / Enabling of option KinematicsComp
Anreise / journey there
Erstellung / Anpassung der Messstrategie an das Maschinenvolumen und an
die
Gegebenheiten vor Ort / Creation and modification of the measurement strategy
and setup for the machine tool and milling head
Temperaturmesssystem installiert / setup of the temperature measuring system
 Konfiguration der Maschinensteuerung / Configuration of CNC Control
Dienstag
Tuesday
Kalibriermessung der Maschine / Calibration measurement of the machine tool
Auswertung der volumetrischen Abweichung / Evaluation of the volumetric deviation
Korrekturfeld erzeugt, installiert und Test der Kompensation / calculation and
installation of error map, function test of volumetric compensation
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 3
Zeitplan / Schedule
Mittwoch
Wednesday
Verifizierungsmessung des kompensierten Volumens / Verification measurement
of the compensated machine tool
Auswertung Verifizierungsmessung
und der Restabweichungen / Evaluation
verification measurement an calcualtion of residual errors
Abreise / Return trip
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 4
Maschine / Machine tool
Kompensationsvolumen /
Compensated workspace: 1,4m³
X-Achse / X-Axis: 2140 mm
Y-Achse / Y-Axis: 800 mm
Z-Achse / Z-Axis: 790 mm
Maschine ohne Herstellerkorrekturen
Machine tool without vendor corrections
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 5
Messgerät / Measurement device: LaserTRACER






Developed especially for the volumetric calibration of
coordinate measuring machines and machine tools
Complete error analysis exclusively by length
measurements (similar to GPS)
Automatic tracking interferometer
Resolution: 1 nm
Length measuring error: 0,2 µm + 0,3 µm/m
Measuring range: 15 m
(extendable by mathematical superposition)
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 6
Ergebnisse / Results
Verification of KinematicsComp on a 3 axis moving column machine tool / Heckert CS800
Parameter
position deviation
[µm]
straightness deviation
[µm]
rotational deviation
[µrad]
orthogonality
[µrad]
Laser length deviation [µm]
Simulated length deviation [µm]
Simulated spatial deviation [µm]
© AfM Technology GmbH
xTx / EXX
yTy / EYY
zTz / EZZ
xTy / EYX
xTz / EZX
yTx / EXY
yTz / EZY
zTx / EXZ
zTy / EYZ
xRx / EAX
xRy / EBX
xRz / ECX
yRy / EBY
yRx / EAY
yRz / ECY
zRz / ECZ
zRx / EAZ
zRy / EBZ
xWy/COY
xWz/BOZ
yWz/AOZ
∆L mea
1D sim
3D sim
Without
Heidenhain
KinComp
330,7
15,5
4,5
25,5
76,6
15,0
25,2
5,8
5,3
89,8
217,0
92,1
27,3
8,2
11,7
17,1
10,5
9,5
-91,9
30,8
64,3
210,0
360,0
274,0
With
Heidenhain
KinComp
Volumetric Compensation of machine tools
U (max)
Improvement
Tracer
14,7
6,1
5,9
7,8
9,1
7,8
9,7
4,3
4,0
7,6
11,8
2,8
12,5
11,0
25,7
19,9
3,7
14,5
-6,1
-4,2
-9,1
28,0
17,0
26,0
0,5
0,3
0,4
0,4
0,5
0,2
0,3
0,3
0,2
1,1
0,3
0,4
0,4
0,3
0,5
0,5
0,5
0,7
0,3
0,5
0,3
0,9
0,9
0,9
absolut
percentage
-316,1
-96%
-9,4
-61%
1,4
31%
-17,7
-69%
-67,5
-88%
-7,1
-48%
-15,5
-61%
-1,4
-25%
-1,3
-24%
-82,3
-92%
-205,1
-95%
-89,3
-97%
-14,8
-54%
2,8
34%
14,1
120%
2,9
17%
-6,9
-65%
5,0
52%
-85,8
-93%
-26,5
-86%
-55,3
-86%
-182,0
-87%
-343,0
-95%
-248,0
-91%
Page 7
Ergebnisse / Results
Verification of KinematicsComp on 3 axis moving column machine tool
Heckert CS800
400,0
350,0
300,0
250,0
200,0
150,0
100,0
50,0
0,0
-50,0
-100,0
Without Heidenhain KinComp
© AfM Technology GmbH
With Heidenhain KinComp
Volumetric Compensation of machine tools
Page 8
Positionsabweichungen / Position deviations
Position deviation x-axis
200,0
100,0
50,0
0,0
-50,0
-30
90
210
330
450
570
690
810
930
1050
1170
1290
1410
1530
1650
1770
1890
2010
X-Axis / Y-Axis / Z-Axis
Deviations related to 20°C
150,0
deviation [µm]
X-Achse / Y-Achse / Z-Achse
Abweichungen bezogen auf 20°C
-100,0
-150,0
xTx / EXX
Position deviation z-axis
200,0
150,0
150,0
100,0
100,0
0,0
-50,0
50,0
0,0
-50,0
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
50,0
deviation [µm]
200,0
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
deviation [µm]
Position deviation y-axis
xTx / EXX with KinComp
-100,0
-100,0
-150,0
-150,0
yTy / EYY
© AfM Technology GmbH
yTy / EYY with KinComp
Volumetric Compensation of machine tools
zTz / EZZ
zTz / EZZ with KinComp
Page 9
Geradheitsabweichungen / Straightness dev.
X-Achse / x-axis
Straightness x-axis in z-direction
80,0
80,0
60,0
60,0
40,0
20,0
-20,0
-30
90
210
330
450
570
690
810
930
1050
1170
1290
1410
1530
1650
1770
1890
2010
0,0
xTy / EYX
© AfM Technology GmbH
40,0
20,0
0,0
-20,0
-30
70
170
270
370
470
570
670
770
870
970
1070
1170
1270
1370
1470
1570
1670
1770
1870
1970
2070
deviation [µm]
deviation [µm]
Straightness x-axis in y-direction
xTy / EYX with KinComp
Volumetric Compensation of machine tools
xTz / EZX
xTz / EZX with KinComp
Page 10
Geradheitsabweichungen / Straightness dev.
Y-Achse / y-axis
Straightness y-axis in z-direction
80,0
80,0
60,0
60,0
deviation [µm]
40,0
20,0
20,0
0,0
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
0,0
-20,0
40,0
yTx / EXY
© AfM Technology GmbH
-20,0
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
deviation [µm]
Straightness y-axis in x-direction
yTx / EXY with KinComp
Volumetric Compensation of machine tools
yTz / EZY
yTz / EZY with KinComp
Page 11
Geradheitsabweichungen / Straightness dev.
Z-Achse / z-axis
Straightness z-axis in y-direction
80,0
80,0
60,0
60,0
deviation [µm]
40,0
20,0
0,0
20,0
0,0
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
-20,0
40,0
zTx / EXZ
© AfM Technology GmbH
-20,0
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
deviation [µm]
Straightness z-axis in x-direction
zTx / EXZ with KinComp
Volumetric Compensation of machine tools
zTy / EYZ
zTy / EYZ with KinComp
Page 12
Rotationsabweichungen / Rotational deviation
X-Achse / x-axis
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-30
90
210
330
450
570
690
810
930
1050
1170
1290
1410
1530
1650
1770
1890
2010
deviation [µrad]
Roll x-axis
xRx / EAX
xRy / EBX
© AfM Technology GmbH
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-30
90
210
330
450
570
690
810
930
1050
1170
1290
1410
1530
1650
1770
1890
2010
deviation [µrad]
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
Yaw x-axis
-30
90
210
330
450
570
690
810
930
1050
1170
1290
1410
1530
1650
1770
1890
2010
deviation [µrad]
Pitch x-axis
xRx / EAX with KinComp
xRy / EBX with KinComp
Volumetric Compensation of machine tools
xRz / ECX
xRz / ECX with KinComp
Page 13
Rotationsabweichungen / Rotational deviation
Y-Achse / y-axis
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
deviation [µrad]
Roll y-axis
yRy / EBY
yRx / EAY
© AfM Technology GmbH
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
deviation [µrad]
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
Yaw y-axis
-765
-725
-685
-645
-605
-565
-525
-485
-445
-405
-365
-325
-285
-245
-205
-165
-125
-85
-45
-5
35
deviation [µrad]
Pitch y-axis
yRy with KinComp
yRx / EAY with KinComp
Volumetric Compensation of machine tools
yRz / ECY
yRz / ECY with KinComp
Page 14
Rotationsabweichungen / Rotational deviation
Z-Achse / z-axis
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
deviation [µrad]
Roll z-axis
zRz / ECZ
zRx / EAZ
© AfM Technology GmbH
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
deviation [µrad]
125,0
100,0
75,0
50,0
25,0
0,0
-25,0
-50,0
-75,0
-100,0
Pitch z-axis
-790
-750
-710
-670
-630
-590
-550
-510
-470
-430
-390
-350
-310
-270
-230
-190
-150
-110
-70
-30
deviation [µrad]
Yaw z-axis
zRz / ECZ with KinComp
zRx / EAZ with KinComp
Volumetric Compensation of machine tools
zRy / EBZ
zRy / EBZ with KinComp
Page 15
Rechtwinkligkeiten / Orthogonality
Squareness xWy / COY
1,000000
xWy/COY
X-Achse / Y-Achse / Z-Achse
xWy/COY
with KinComp
X-Axis / Y-Axis / Z-Axis
0,000000
deviation [µrad]
Squareness yWz / AOZ
Squareness xWz / BOZ
1,000000
1,000000
0,000000
xWz/BOZ
yWz/AOZ
xWz/BOZ
with KinComp
yWz/AOZ
with KinComp
0,000000
deviation [µrad]
deviation [µrad]
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 16
1D Abweichung / 1D deviation
without
Volumetric Compensation
Maximum 360 µm deviation
1D Abweichung: Es wurden die
Abweichungen entlang achsparalleler
Geraden, in allen Ebenen- und in allen
Raumdiagonalen berechnet.
© AfM Technology GmbH
with
Volumetric Compensation
Maximum 17µm deviation
1D deviation: The maximum deviation
of measuring lines along the axes, in
all planes and all spatial diagonals of the
work space
Volumetric Compensation of machine tools
Page 17
2D Abweichung / 2D deviation
Without Volumetric Compensation
Maximum 228 µm deviation
2D Abweichung: Es wurde die maximale
volumetrische Abweichung in der X-Y
Ebene bei Z = -790 mm berechnet
© AfM Technology GmbH
With Volumetric Compensation
Maximum 23 µm deviation
2D deviation: The maximum
volumetric deviation in the X-Y plane at
-790 mm Z position of the machine tool
Volumetric Compensation of machine tools
Page 18
3D Abweichung / 3D deviation
Without Volumetric Compensation
Maximum 274 µm deviation
3D Abweichung: Es wurde die maximale
volumetrische Abweichung im gesamten
Arbeitsraum berechnet
© AfM Technology GmbH
With Volumetric Compensation
Maximum 26 µm deviation
3D deviation: The maximum volumetric
deviation in the whole workspace of the
machine tool
Volumetric Compensation of machine tools
Page 19
Messablauf / Measuring schedule
LaserTRACER-Measurement / 3 axis moving column machine tool / Heckert CS800
Calibration
Measurement
1
2
3
4
5
6
7
8
Position Actual Nominal
2
1
4
3
6
5
8
7
307
307
307
307
311
311
311
311
Date
Start time End time
307
307
307
307
311
311
311
311
Duration
tp [s] Start temp. End temp.
0:17:32
0:17:37
0:17:42
0:17:34
0:12:32
0:13:00
0:13:06
0:13:22
3,43
3,44
3,46
3,43
2,42
2,51
2,53
2,58
19,513
19,840
20,206
20,276
19,939
20,069
20,138
20,019
19,609
19,883
20,171
20,488
20,001
19,977
20,142
19,848
Temp. diff. Gradient [°C/h] Average
0,096
0,044
-0,035
0,212
0,061
-0,091
0,004
-0,170
0,329
0,148
-0,120
0,724
0,294
-0,422
0,018
-0,765
19,561
19,861
20,189
20,382
19,970
20,023
20,140
19,934
Verification
Measurement
1
2
3
4
5
6
7
Position Actual Nominal
7
8
5
6
4
2
1
311
311
311
311
307
299
299
Date
Start time End time
311
311
311
311
307
299
299
Duration
tp [s] Start temp. End temp.
0:19:15
0:13:42
0:12:49
0:12:27
0:19:08
0:19:26
0:25:19
3,71
2,64
2,47
2,40
3,74
3,90
5,08
18,147
18,341
18,457
18,617
19,384
19,435
19,263
18,318
18,238
18,481
18,626
19,362
19,257
19,125
Temp. diff. Gradient [°C/h] Average
0,171
-0,103
0,024
0,009
-0,022
-0,178
-0,137
0,534
-0,452
0,111
0,043
-0,068
-0,549
-0,325
18,232
18,290
18,469
18,622
19,373
19,346
19,194
Measuring schedule
Duration [hh:mm:ss]
measurement time
setup time
total time
© AfM Technology GmbH
Calibration
2:02:25
2:25:55
4:28:20
Verification
2:02:06
5:17:07
7:19:13
Volumetric Compensation of machine tools
Page 20
18:50:00
19:43:00
20:36:00
21:29:00
22:22:00
23:15:00
00:08:00
01:01:00
01:54:00
02:47:00
03:40:00
04:33:00
05:26:00
06:19:00
07:12:00
08:05:00
08:58:00
09:51:00
10:44:00
11:37:00
12:30:00
13:23:00
14:16:00
15:09:00
16:02:00
16:55:00
17:48:00
18:41:00
19:34:00
20:27:00
21:20:00
22:13:00
23:06:00
23:59:00
00:52:00
01:45:00
02:38:00
03:31:00
04:24:00
05:17:00
06:10:00
07:03:00
07:56:00
08:49:00
09:42:00
10:35:00
11:28:00
12:21:00
13:14:00
14:07:00
15:00:00
15:53:00
16:46:00
17:39:00
18:32:00
Temperatur Bedingungen / Temperature conditions
Temperature over time
22,00
Calibration
Y-Axis
© AfM Technology GmbH
X-Axis
Verification
21,00
20,00
19,00
18,00
17,00
16,00
15,00
Air
Z-Axis (-)
Z-Axis (+)
Volumetric Compensation of machine tools
Page 21
Thank you for your attention
Vielen Dank für Ihre Aufmerksamkeit
Grazie per la vostra attenzione
Ansprechpartner Italien
AfM Technology GmbH
Roland Rauch
Gartenstraße 133
Mobile: +39 348 4221124
73430 Aalen / Germany
www.afm-tec.com
Fon: +49 (0)7361 889608-0
[email protected]
Fax: +49 (0)7361 889608-99
www.afm-tec.de • [email protected]
© AfM Technology GmbH
Volumetric Compensation of machine tools
Page 22

Proofs - ProvenTrue

IMS Data Sheet - Newport Corporation