Compensation of Tool Deflection in Robotic-Based Milling

International audienceThe paper presents the compliance errors compensation technique for industrial robots, which are used in milling manufacturing cells. under external loading, which is based on the non-linear stiffness model. In contrast to previous works, it takes into account the interaction between the milling tool and the workpiece that depends on the end-effector position, process parameters and cutting conditions (spindle rotation, feed rate, geometry of the tool, etc.). Within the developed technique, the compensation errors caused by external loading is based on the non-linear stiffness model and reduces to a proper adjusting of a target trajectory that is modified in the off-line mode. The advantages and practical significance of the proposed technique are illustrated by an example that deals with milling with Kuka robot

Compliance error compensation in robotic-based milling

The paper deals with the problem of compliance errors compensation in robotic-based milling. Contrary to previous works that assume that the forces/torques generated by the manufacturing process are constant, the interaction between the milling tool and the workpiece is modeled in details. It takes into account the tool geometry, the number of teeth, the feed rate, the spindle rotation speed and the properties of the material to be processed. Due to high level of the disturbing forces/torques, the developed compensation technique is based on the non-linear stiffness model that allows us to modify the target trajectory taking into account nonlinearities and to avoid the chattering effect. Illustrative example is presented that deals with robotic-based milling of aluminum alloy

Compliance error compensation technique for parallel robots composed of non-perfect serial chains

The paper presents the compliance errors compensation technique for over-constrained parallel manipulators under external and internal loadings. This technique is based on the non-linear stiffness modeling which is able to take into account the influence of non-perfect geometry of serial chains caused by manufacturing errors. Within the developed technique, the deviation compensation reduces to an adjustment of a target trajectory that is modified in the off-line mode. The advantages and practical significance of the proposed technique are illustrated by an example that deals with groove milling by the Orthoglide manipulator that considers different locations of the workpiece. It is also demonstrated that the impact of the compliance errors and the errors caused by inaccuracy in serial chains cannot be taken into account using the superposition principle.Comment: arXiv admin note: text overlap with arXiv:1204.175

Modèle des interactions dynamiques

In robotic-based machining, an interaction between the workpiece and technological tool causes essential deflections that significantly decrease the manufacturing accuracy. Relevant compliance errors highly depend on the manipulator configuration and essentially differ throughout the workspace. Their influence is especially important for heavy serial robots. To overcome this difficulty this report presents a new technique for compensation of the compliance errors caused by technological process. In contrast to previous works, this technique is based on the non-linear stiffness model and the reduced elasto-dynamic model of the robotic based milling process. The advantages and practical significance of the proposed approach are illustrated by milling with of KUKA KR270. It is shown that after error compensation technique significantly increase the accuracy of milling.ANR COROUSS

Compensation of compliance errors in parallel manipulators composed of non-perfect kinematic chains

The paper is devoted to the compliance errors compensation for parallel manipulators under external loading. Proposed approach is based on the non-linear stiffness modeling and reduces to a proper adjusting of a target trajectory. In contrast to previous works, in addition to compliance errors caused by machining forces, the problem of assembling errors caused by inaccuracy in the kinematic chains is considered. The advantages and practical significance of the proposed approach are illustrated by examples that deal with groove milling with Orthoglide manipulator.Comment: Advances in Robot Kinematics, France (2012

Stiffness modeling of robotic manipulator with gravity compensator

The paper focuses on the stiffness modeling of robotic manipulators with gravity compensators. The main attention is paid to the development of the stiffness model of a spring-based compensator located between sequential links of a serial structure. The derived model allows us to describe the compensator as an equivalent non-linear virtual spring integrated in the corresponding actuated joint. The obtained results have been efficiently applied to the stiffness modeling of a heavy industrial robot of the Kuka family

FEA-based design study for optimising non-rigid error detection on machine tools

Non-rigid-body behaviour can have a considerable effect on the overall accuracy performance of machine tools. These errors originate from bending of the machine structure due to change in distribution of its own weight or from movement of the workpiece and fixture. These effects should be reduced by good mechanical design, but residual errors can still be problematic due to realistic material and cost limitations. One method of compensation is to measure the deformation directly with sensors embedded in a metrology frame. This paper presents an FEA-based design study which assesses finite stiffness effects in both the machine structure and its foundation to optimise the sensitivity of the frame to the resulting errors. The study results show how a reference artefact, optimised by the FEA study, can be used to detect the distortion

Compliance error compensation in robotic-based milling

The paper deals with the problem of compliance errors compensation in robotic-based milling. Contrary to previous works that assume that the forces/torques generated by the manufacturing process are constant, the interaction between the milling tool and the workpiece is modeled in details. It takes into account the tool geometry, the number of teeth, the feed rate, the spindle rotation speed and the properties of the material to be processed. Due to high level of the disturbing forces/torques, the developed compensation technique is based on the non-linear stiffness model that allows us to modify the target trajectory taking into account nonlinearities and to avoid the chattering effect. Illustrative example is presented that deals with robotic-based milling of aluminum alloy

Stiffness modeling of non-perfect parallel manipulators

The paper focuses on the stiffness modeling of parallel manipulators composed of non-perfect serial chains, whose geometrical parameters differ from the nominal ones. In these manipulators, there usually exist essential internal forces/torques that considerably affect the stiffness properties and also change the end-effector location. These internal load-ings are caused by elastic deformations of the manipulator ele-ments during assembling, while the geometrical errors in the chains are compensated for by applying appropriate forces. For this type of manipulators, a non-linear stiffness modeling tech-nique is proposed that allows us to take into account inaccuracy in the chains and to aggregate their stiffness models for the case of both small and large deflections. Advantages of the developed technique and its ability to compute and compensate for the compliance errors caused by different factors are illustrated by an example that deals with parallel manipulators of the Or-thoglide famil