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Vision measurement system for position-dependent geometric error calibration of five-axis machine tools

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Abstract

The geometric error calibration of rotary axes is a key procedure for improving the machining accuracy of five-axis machine tools. In conventional research, the measurement scheme is mainly based on commercial instruments (e.g., the laser tracker, double-ball bar, and R-test). In this study, a vision-based measurement system and an identification algorithm are proposed to measure three-dimensional (3D) displacement and identify 10 position-dependent geometric errors (PDGEs) in the rotary axis (A and C axes). First, based on a high-precision microscopic checkerboard, the 3D displacement of a chessboard corner is identified using the depth-of-focus method (in the z direction) and the OpenCV corner detection method (in the x and y directions). Second, a simplified error identification model is proposed to identify the 10 PDGEs. Then, the vision system is established to reduce the interference of other installation errors and separate the PDGEs of the A and C axes. Its measurement performance is compared to the R-test. Experimental case studies show that PDGEs are reduced by approximately ten times after compensation, and it proves the accuracy and feasibility of the vision measurement system.

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Data availability

The data sets supporting the results of this article are available from the corresponding author on reasonable request.

Code availability

The code used during the current study is available from the corresponding author on reasonable request.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Weihua Chen, Bingran Li, Tong Zhao, Hui Zhang & Peiqing Ye

  2. Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing, China

    Weihua Chen, Bingran Li, Tong Zhao & Hui Zhang

  3. Tsinghua University, Room A946-2, Lee Shau-Kee Science & Technology Building, Beijing, China

    Bingran Li

  4. The State Key Laboratory of Tribology, Tsinghua University, Beijing, China

    Peiqing Ye

Authors
  1. Weihua Chen
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  2. Bingran Li
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  3. Tong Zhao
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  4. Hui Zhang
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  5. Peiqing Ye
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Contributions

All the authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Weihua Chen and Bingran Li. The first draft of the manuscript was written by Weihua Chen, and all the authors commented on previous versions of the manuscript. All the authors read and approved the final manuscript.

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Correspondence to Bingran Li.

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Chen, W., Li, B., Zhao, T. et al. Vision measurement system for position-dependent geometric error calibration of five-axis machine tools. Int J Adv Manuf Technol 123, 3969–3981 (2022). https://doi.org/10.1007/s00170-022-10274-4

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  • DOI: https://doi.org/10.1007/s00170-022-10274-4

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