Positioning Error Analysis and Compensation of Differential Precision Workbench
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The document analyzes positioning errors in differential precision workbenches and proposes a compensation method. It discusses sources of error in workbench transmission systems and guides. Through theoretical analysis and experimentation, it is shown that positioning errors increase with travel distance due to factors like guideway errors. A method is developed to sample positioning at multiple points, compare values to identify errors, and implement reverse error correction through motion control cards. This allows positioning accuracy better than 15 micrometers over 150mm of travel to be achieved. The compensation method can improve precision for a range of machine tool designs.
![International Journal of Research in Engineering and Science (IJRES)
ISSN (Online): 2320-9364, ISSN (Print): 2320-9356
www.ijres.org Volume 4 Issue 1 ǁ January. 2016 ǁ PP.69-73
www.ijres.org 69 | Page
Positioning Error Analysis and Compensation of Differential
Precision Workbench
Boyan Ding1
, Minliang Zhang2
, Yi Li3
, Zhengyuan Cheng4
, Zhijie Zhang5
(Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620)
(Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620)
(Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620)
(Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620)
(Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620)
Abstract: Positioning error is a widely problem exists in mechanism, the important factors affecting machining
precision. In order to reduce the error caused by positioning problem processing, based on the differential
workbench as the research object, using the method of theoretical analysis and experimental verification, the
analysis of positioning error mechanism and source of complete differential precision workbench error
compensation, improve the accuracy of the device, provides a method for the application of modern machine
tools. table.
Key words: Position error; Differential workbench; Compensation method
I. Introduction
Precision measurement is one of the basis of the key about the common modern high science technology
and it is one of the sophisticated industrial production. Scientific research occupies an extremely important
position, has a broad application prospect. Precision and ultra-precision processing technology is one of the
most important development direction of modern machinery manufacturing, is the modern aerospace,
microelectronics, optical, robot, biology, medicine, and the basis for the development of advanced technology
such as genetic engineering[1.]
.How to improve the positioning accuracy of machine tool is convenient and
economic research topic in all aspects, now correct measure machine tool positioning and use appropriate error
compensation method of positioning error compensation is the key to improve the machine tool positioning
accuracy[2.]
.
II. The introduce of the differential precision worktable
This topic device using the upper and lower two levels of independent workbench superposition, choose
Nanjing process equipment co., LTD. Nc-precision table as differential precision worktable system of upper and
lower workbench, transformation model for SZHT4020T-P3[3.]
.Differential precision workbench trip 200 mm
and 400 mmrespectively, ball screw lead to 5 mm,the whole differential workbench device is through a steel
plate fixed on the upper base table, differential precision worktable by separate smooth guiding rail, precision of
transmission system and the workbench, and absolute position measuring device is to use feedback linear
grating grating measurement, receive differential workbench actual location and real-time feedback to the upper
control system, and issue instructions for comparative analysis, and other functions.
Motion control card, which is the core of the system control, can control servo motor movement, can also](https://image.slidesharecdn.com/l4016973-160226092757/85/Positioning-Error-Analysis-and-Compensation-of-Differential-Precision-Workbench-1-320.jpg)
![Position Error Analysis and compensation of Differential Precision Workbench
www.ijres.org 70 | Page
receive feedback signal, comparing the position error, feedback to the PC[4.]
.Ac servo motor is connected motion
control card and mechanical transmission mechanism of signal transmission bridge,as a motor
actuators,corresponding with their respective servo drive device,according to the instructions from the PC to
complete the rotary motion, mechanical transmission mechanism to servo motor rotation movement into linear
motion table, using the built-in rotary encoder to control feedback pulse data.
CPU
Computer
Bus
Motion
Control
Card
Actuator
Actuator
Ac Servo
Motor
As Servo
Motor
Encoder
Encoder
Table 1
Table 2
Mutual superposition
Linear Grating
Fig.1 Overall design of system structure
III. The principle of differential motion analysis
Differential precision workbench using two workbench,similar to the macro and micro bench work.By
applying the differential structure of two ball screw system,to reduce the positioning error of the differential
system,realize the higher positioning accuracy,so as to realize the localization accuracy of mechanical system of
equipment agency requirements[5.]
.Differential ball screw feed system principle of work is as follows:
Motor1
Motor2
Coupling
Coupling
Ball Screw 1
Ball Screw2
Table1
Table2
ΔL=ΔL2-ΔL1
Fig.2 The principle diagram of the differential
The differential principle is: the movement of the table 1 and table 2 difference is relative to the ground
displacement.Ac servo motor to receive after sending the instruction to the motion control system,in accordance
with the instructions of the pulse,rotary motion to drive the ball screw,ball screw rotation of the motor can be
converted to the linear motion of the workbench [4]
.In the process of differential,ball screw 1 and 2 direction is
the same,the turning of the servo motor 1 and 2 are the same.The 12 LLL ,Which is the output of the
differential precision worktable.
The movement volume can be calculated by the following formula:
2 2
k n
L
(1)](https://image.slidesharecdn.com/l4016973-160226092757/85/Positioning-Error-Analysis-and-Compensation-of-Differential-Precision-Workbench-2-320.jpg)
![Position Error Analysis and compensation of Differential Precision Workbench
www.ijres.org 72 | Page
Fig.4 The sampling point positioning accuracy of differential workbench
Differential precision worktable controlled by motion control card, completed the differential movement,
table1 and table2, respectively under 150 mm 300 mm trip biggest positioning error respectively 15 m , 8
m (40 pulses and 24 pulses).Because there is a cumulative pitch error, with experimental measurement
analysis for many times. error of guide way and bearing, etc., as the error of the differential workbench have the
tendency of increase with the increase gradually. Through the analysis of the third chapter, we know, precision
grating and the parallelism workbench and lead to differential table 1 error change is bigger, the abbe error is
discussed, along with the increase of the displacement error is gradually increased.
V. Conclusion
Through the above theoretical research and experimental analysis differential positioning precision
worktable compensation is realized. To explore the differential movement form error compensation method,
improve the system precision and sensitivity, to engineering application provides an effective method to
improve the precision of table. The method can be applied to the existing conditions of different structure design
and the appropriate compensation method to satisfy the whole system of high precision and large travel
requirements, and for the design of micro-feed mechanism to provide a new train of thought.
VI. Acknowledgements
The authors would like to thank the financial support from Scientific Research Innovation Fund of
Shanghai University of Engineering Science and the school’s lab conditions to this research.
Reference
[1.] Ren Ping Shao, Mechanical system dynamics[M], Beijing, China Machine Press 2005
[2.] Pei Gong Wang, The dynamic modeling and dynamical optimum designing of the XK717 numerical
control milling[D].Zhejiang Poly technical University.2005.5
[3.] Galil Motion Control; Inc. DMC-21x2/21x3 User Manual Rev.1.0h[M].USA.2009.
[4.] JunLi, JunWen Xing, WenZhi Qin, ADAMS instance tutorial[M]. Beijing:Beijing Institute OF
Technology,2002.19-46
[5.] Jian Rong Zheng. ADAMS virtual prototype technology introduction and improvement [M].](https://image.slidesharecdn.com/l4016973-160226092757/85/Positioning-Error-Analysis-and-Compensation-of-Differential-Precision-Workbench-4-320.jpg)
![Position Error Analysis and compensation of Differential Precision Workbench
www.ijres.org 73 | Page
Beijing,China Machine Press.2001:97-100
[6.] Chen JS,Huang YK，Cheng CC,Mechanical model and contouring analysis of high speed ball screw
drive systems with compliance effect [J],IntJ Adv.Manuf Technology.2004.(24):241—245
[7.] Geometric error measurement and compensation of machines—An update CIRP
Annals—Manufacturing Technology 57(2008) 660—675
[8.] Peng Yuxin;Gao Wei; Kaneko Jun;et al. A linear micro-stage with a long stroke for precision
positioning of micro-objects [J]. Nanotechnology and Precision Engineering.2011.09(3):221-227.
[9.] A degree-of-freedom measurement system for the accuracy of X-Y stages Precision Engineering
24(2000) 15-23
[10.] D.Dornfeld.S. Min.Y. Takeuchi. Recent Advances in Mechanical Micro-machining[J]. CIRP
Annals.2006.55(2):745-768.](https://image.slidesharecdn.com/l4016973-160226092757/85/Positioning-Error-Analysis-and-Compensation-of-Differential-Precision-Workbench-5-320.jpg)
Positioning Error Analysis and Compensation of Differential Precision Workbench
- 1. International Journal of Research in Engineering and Science (IJRES) ISSN (Online): 2320-9364, ISSN (Print): 2320-9356 www.ijres.org Volume 4 Issue 1 ǁ January. 2016 ǁ PP.69-73 www.ijres.org 69 | Page Positioning Error Analysis and Compensation of Differential Precision Workbench Boyan Ding1 , Minliang Zhang2 , Yi Li3 , Zhengyuan Cheng4 , Zhijie Zhang5 (Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620) (Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620) (Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620) (Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620) (Department of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai China,201620) Abstract: Positioning error is a widely problem exists in mechanism, the important factors affecting machining precision. In order to reduce the error caused by positioning problem processing, based on the differential workbench as the research object, using the method of theoretical analysis and experimental verification, the analysis of positioning error mechanism and source of complete differential precision workbench error compensation, improve the accuracy of the device, provides a method for the application of modern machine tools. table. Key words: Position error; Differential workbench; Compensation method I. Introduction Precision measurement is one of the basis of the key about the common modern high science technology and it is one of the sophisticated industrial production. Scientific research occupies an extremely important position, has a broad application prospect. Precision and ultra-precision processing technology is one of the most important development direction of modern machinery manufacturing, is the modern aerospace, microelectronics, optical, robot, biology, medicine, and the basis for the development of advanced technology such as genetic engineering[1.] .How to improve the positioning accuracy of machine tool is convenient and economic research topic in all aspects, now correct measure machine tool positioning and use appropriate error compensation method of positioning error compensation is the key to improve the machine tool positioning accuracy[2.] . II. The introduce of the differential precision worktable This topic device using the upper and lower two levels of independent workbench superposition, choose Nanjing process equipment co., LTD. Nc-precision table as differential precision worktable system of upper and lower workbench, transformation model for SZHT4020T-P3[3.] .Differential precision workbench trip 200 mm and 400 mmrespectively, ball screw lead to 5 mm,the whole differential workbench device is through a steel plate fixed on the upper base table, differential precision worktable by separate smooth guiding rail, precision of transmission system and the workbench, and absolute position measuring device is to use feedback linear grating grating measurement, receive differential workbench actual location and real-time feedback to the upper control system, and issue instructions for comparative analysis, and other functions. Motion control card, which is the core of the system control, can control servo motor movement, can also
- 2. Position Error Analysis and compensation of Differential Precision Workbench www.ijres.org 70 | Page receive feedback signal, comparing the position error, feedback to the PC[4.] .Ac servo motor is connected motion control card and mechanical transmission mechanism of signal transmission bridge,as a motor actuators,corresponding with their respective servo drive device,according to the instructions from the PC to complete the rotary motion, mechanical transmission mechanism to servo motor rotation movement into linear motion table, using the built-in rotary encoder to control feedback pulse data. CPU Computer Bus Motion Control Card Actuator Actuator Ac Servo Motor As Servo Motor Encoder Encoder Table 1 Table 2 Mutual superposition Linear Grating Fig.1 Overall design of system structure III. The principle of differential motion analysis Differential precision workbench using two workbench,similar to the macro and micro bench work.By applying the differential structure of two ball screw system,to reduce the positioning error of the differential system,realize the higher positioning accuracy,so as to realize the localization accuracy of mechanical system of equipment agency requirements[5.] .Differential ball screw feed system principle of work is as follows: Motor1 Motor2 Coupling Coupling Ball Screw 1 Ball Screw2 Table1 Table2 ΔL=ΔL2-ΔL1 Fig.2 The principle diagram of the differential The differential principle is: the movement of the table 1 and table 2 difference is relative to the ground displacement.Ac servo motor to receive after sending the instruction to the motion control system,in accordance with the instructions of the pulse,rotary motion to drive the ball screw,ball screw rotation of the motor can be converted to the linear motion of the workbench [4] .In the process of differential,ball screw 1 and 2 direction is the same,the turning of the servo motor 1 and 2 are the same.The 12 LLL ,Which is the output of the differential precision worktable. The movement volume can be calculated by the following formula: 2 2 k n L (1)
- 3. Position Error Analysis and compensation of Differential Precision Workbench www.ijres.org 71 | Page Among them: is the angular displacement of the servo motor. is the guide of the ball screw. n is represent for the number of the pulse instruction. k is the proportion co-efficient of the servo system.They have related to the servo system hardware structure. According to the principle of the ball screw differential diagram: 21, are the upper and lower two pairs of the ball screw lead. 21,nn are the numbers of the feeding pulse of control system. 21,kk are the ratio of the servo control system. The respectively actual amount of the each instruction displacement of table and table 2: 1 1 1 1 2 k n L (2) 2 2 2 2 2 k n L (3) The micro-displacement of differential workbench is: 2 2 1 1 2 1 2 1 2 2 k n k n L L L (4) IV. The Positioning error compensation method Differential positioning error compensation method, the differential sampling precision worktable transmission end position, to get the actual samples values and compare the ideal value,the design of reverse error correction of differential system compensation, eliminate differential positioning error,error compensation principle as shown in the figure below: 位移 （mm） ΔL 时间（t）t0 理想位移 实际位移 Fig.3 Position error compensation workbench principle The error of the differential workbench is: 2 hL x P (5) Among them: L is the position error of system; x is the actual displacement measured by the man. is the transmission angle of ball screw. hP is the lead of ball screw. As mentioned earlier,differential precision workbench is divided into upper and lower two levels of workbench with journey of 200 mm and 400 mm respectively.Motion control card initialization parameter to 5 mm sampling spacing for the unit,each pulse value of 0.5 m .Respectively on two levels bench sampling the same point,comparing multiple sampling.We can get the position precision of table1 and table 2,under the differential form.
- 4. Position Error Analysis and compensation of Differential Precision Workbench www.ijres.org 72 | Page Fig.4 The sampling point positioning accuracy of differential workbench Differential precision worktable controlled by motion control card, completed the differential movement, table1 and table2, respectively under 150 mm 300 mm trip biggest positioning error respectively 15 m , 8 m (40 pulses and 24 pulses).Because there is a cumulative pitch error, with experimental measurement analysis for many times. error of guide way and bearing, etc., as the error of the differential workbench have the tendency of increase with the increase gradually. Through the analysis of the third chapter, we know, precision grating and the parallelism workbench and lead to differential table 1 error change is bigger, the abbe error is discussed, along with the increase of the displacement error is gradually increased. V. Conclusion Through the above theoretical research and experimental analysis differential positioning precision worktable compensation is realized. To explore the differential movement form error compensation method, improve the system precision and sensitivity, to engineering application provides an effective method to improve the precision of table. The method can be applied to the existing conditions of different structure design and the appropriate compensation method to satisfy the whole system of high precision and large travel requirements, and for the design of micro-feed mechanism to provide a new train of thought. VI. Acknowledgements The authors would like to thank the financial support from Scientific Research Innovation Fund of Shanghai University of Engineering Science and the school’s lab conditions to this research. Reference [1.] Ren Ping Shao, Mechanical system dynamics[M], Beijing, China Machine Press 2005 [2.] Pei Gong Wang, The dynamic modeling and dynamical optimum designing of the XK717 numerical control milling[D].Zhejiang Poly technical University.2005.5 [3.] Galil Motion Control; Inc. DMC-21x2/21x3 User Manual Rev.1.0h[M].USA.2009. [4.] JunLi, JunWen Xing, WenZhi Qin, ADAMS instance tutorial[M]. Beijing:Beijing Institute OF Technology,2002.19-46 [5.] Jian Rong Zheng. ADAMS virtual prototype technology introduction and improvement [M].
- 5. Position Error Analysis and compensation of Differential Precision Workbench www.ijres.org 73 | Page Beijing,China Machine Press.2001:97-100 [6.] Chen JS,Huang YK，Cheng CC,Mechanical model and contouring analysis of high speed ball screw drive systems with compliance effect [J],IntJ Adv.Manuf Technology.2004.(24):241—245 [7.] Geometric error measurement and compensation of machines—An update CIRP Annals—Manufacturing Technology 57(2008) 660—675 [8.] Peng Yuxin;Gao Wei; Kaneko Jun;et al. A linear micro-stage with a long stroke for precision positioning of micro-objects [J]. Nanotechnology and Precision Engineering.2011.09(3):221-227. [9.] A degree-of-freedom measurement system for the accuracy of X-Y stages Precision Engineering 24(2000) 15-23 [10.] D.Dornfeld.S. Min.Y. Takeuchi. Recent Advances in Mechanical Micro-machining[J]. CIRP Annals.2006.55(2):745-768.