A Real-Time Tool Positioning Sensor for Machine-Tools

In machining, natural oscillations, and elastic, gravitational or temperature deformations, are still a problem to guarantee the quality of fabricated parts. In this paper we present an optical measurement system designed to track and localize in 3D a reference retro-reflector close to the machine-tool's drill. The complete system and its components are described in detail. Several tests, some static (including impacts and rotations) and others dynamic (by executing linear and circular trajectories), were performed on two different machine tools. It has been integrated, for the first time, a laser tracking system into the position control loop of a machine-tool. Results indicate that oscillations and deformations close to the tool can be estimated with micrometric resolution and a bandwidth from 0 to more than 100 Hz. Therefore this sensor opens the possibility for on-line compensation of oscillations and deformations

A novel haptic model and environment for maxillofacial surgical operation planning and manipulation

This paper presents a practical method and a new haptic model to support manipulations of bones and their segments during the planning of a surgical operation in a virtual environment using a haptic interface. To perform an effective dental surgery it is important to have all the operation related information of the patient available beforehand in order to plan the operation and avoid any complications. A haptic interface with a virtual and accurate patient model to support the planning of bone cuts is therefore critical, useful and necessary for the surgeons. The system proposed uses DICOM images taken from a digital tomography scanner and creates a mesh model of the filtered skull, from which the jaw bone can be isolated for further use. A novel solution for cutting the bones has been developed and it uses the haptic tool to determine and define the bone-cutting plane in the bone, and this new approach creates three new meshes of the original model. Using this approach the computational power is optimized and a real time feedback can be achieved during all bone manipulations. During the movement of the mesh cutting, a novel friction profile is predefined in the haptical system to simulate the force feedback feel of different densities in the bone

A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines

Development of a Novel MultiBody Mechatronic Model for Five-Axis CNC Machine Tool

The paper presents the development of a mechatronic hybrid model for Geiss five-axis CNC machine tool using MultiBody-System (MBS) approach. The motion control systems comprising electrical and mechanical elements are analyzed and modeled. The 3D assembly of the machine tool is built in SolidWorks and exported into SimMechanics which interfaces seamlessly with SimPowerSystems, SimDriveline, and Simulink packages. CNC machine tools are mechatronic systems incorporating non-linearities so the proposed multibody mechatronic model (which considers the coupling of elastic mechanical structures with the control systems) represents accurately the dynamic behaviour of the actual machine by using only one simulation environment

Measurements by A LEAP-Based Virtual Glove for the hand rehabilitation

Hand rehabilitation is fundamental after stroke or surgery. Traditional rehabilitation requires a therapist and implies high costs, stress for the patient, and subjective evaluation of the therapy effectiveness. Alternative approaches, based on mechanical and tracking-based gloves, can be really effective when used in virtual reality (VR) environments. Mechanical devices are often expensive, cumbersome, patient specific and hand specific, while tracking-based devices are not affected by these limitations but, especially if based on a single tracking sensor, could suffer from occlusions. In this paper, the implementation of a multi-sensors approach, the Virtual Glove (VG), based on the simultaneous use of two orthogonal LEAP motion controllers, is described. The VG is calibrated and static positioning measurements are compared with those collected with an accurate spatial positioning system. The positioning error is lower than 6 mm in a cylindrical region of interest of radius 10 cm and height 21 cm. Real-time hand tracking measurements are also performed, analysed and reported. Hand tracking measurements show that VG operated in real-time (60 fps), reduced occlusions, and managed two LEAP sensors correctly, without any temporal and spatial discontinuity when skipping from one sensor to the other. A video demonstrating the good performance of VG is also collected and presented in the Supplementary Materials. Results are promising but further work must be done to allow the calculation of the forces exerted by each finger when constrained by mechanical tools (e.g., peg-boards) and for reducing occlusions when grasping these tools. Although the VG is proposed for rehabilitation purposes, it could also be used for tele-operation of tools and robots, and for other VR applications

Efficient estimation by FEA of machine tool distortion due to environmental temperature perturbations

Machine tools are susceptible to exogenous influences, which mainly derive from varying environmental conditions such as the day and night or seasonal transitions during which large temperature swings can occur. Thermal gradients cause heat to flow through the machine structure and results in non-linear structural deformation whether the machine is in operation or in a static mode. These environmentally stimulated deformations combine with the effects of any internally generated heat and can result in significant error increase if a machine tool is operated for long term regimes. In most engineering industries, environmental testing is often avoided due to the associated extensive machine downtime required to map empirically the thermal relationship and the associated cost to production. This paper presents a novel offline thermal error modelling methodology using finite element analysis (FEA) which significantly reduces the machine downtime required to establish the thermal response. It also describes the strategies required to calibrate the model using efficient on-machine measurement strategies. The technique is to create an FEA model of the machine followed by the application of the proposed methodology in which initial thermal states of the real machine and the simulated machine model are matched. An added benefit is that the method determines the minimum experimental testing time required on a machine; production management is then fully informed of the cost-to-production of establishing this important accuracy parameter. The most significant contribution of this work is presented in a typical case study; thermal model calibration is reduced from a fortnight to a few hours. The validation work has been carried out over a period of over a year to establish robustness to overall seasonal changes and the distinctly different daily changes at varying times of year. Samples of this data are presented that show that the FEA-based method correlated well with the experimental results resulting in the residual errors of less than 12 μm

Thermal Error Modelling of a CNC Machine Tool Feed Drive System using FEA Method

Recirculating ball screw systems are commonly used in machine tools and are one of the major heat sources which cause considerable thermal drift in CNC machine tools. Finite Element Analysis (FEA) method has been used successfully in the past to model the thermal characteristics of machine tools with promising results. Since FEA predictions are highly dependent on the efficacy of numerical parameters including the surrounding Boundary Conditions (BC), this study emphasises on an efficient modelling method to obtain optimised numerical parameters for acquiring a qualitative response from the feed drive system model. This study was performed on a medium size Vertical Machining Centre (VMC) feed drive system in which two parameter dentification methods have been employed; the general prediction method based on formulae provided by OEMs, and the energy balance method. The parameters obtained from both methods were applied to the FEA model of the machine feed drive system and validated against experimental results. Correlation with which was increased from 70 % to 80 % using the energy balance method

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Optimized estimator for real-time dynamic displacement measurement using accelerometers

This paper presents a method for optimizing the performance of a real-time, long term, and accurate accelerometer based displacement measurement technique, with no physical reference point. The technique was applied in a system for measuring machine frame displacement. The optimizer has three objectives with the aim to minimize phase delay, gain error and sensor noise. A multi-objective genetic algorithm was used to find Pareto optimal estimator parameters. The estimator is a combination of a high pass filter and a double integrator. In order to reduce the gain and phase errors two approaches have been used: zero placement and pole-zero placement. These approaches were analysed based on noise measurement at 0g-motion and compared. Only the pole-zero placement approach met the requirements for phase delay, gain error, and sensor noise. Two validation experiments were carried out with a Pareto optimal estimator. First, long term measurements at 0g-motion with the experimental setup were carried out, which showed displacement error of 27.6 ± 2.3 nm. Second, comparisons between the estimated and laser interferometer displacement measurements of the vibrating frame were conducted. The results showed a discrepancy lower than 2 dB at the required bandwidth