Thermal error modelling of machine tools based on ANFIS with fuzzy c-means clustering using a thermal imaging camera

Thermal errors are often quoted as being the largest contributor to CNC machine tool errors, but they can be effectively reduced using error compensation. The performance of a thermal error compensation system depends on the accuracy and robustness of the thermal error model and the quality of the inputs to the model. The location of temperature measurement must provide a representative measurement of the change in temperature that will affect the machine structure. The number of sensors and their locations are not always intuitive and the time required to identify the optimal locations is often prohibitive, resulting in compromise and poor results. In this paper, a new intelligent compensation system for reducing thermal errors of machine tools using data obtained from a thermal imaging camera is introduced. Different groups of key temperature points were identified from thermal images using a novel schema based on a Grey model GM (0, N) and Fuzzy c-means (FCM) clustering method. An Adaptive Neuro-Fuzzy Inference System with Fuzzy c-means clustering (FCM-ANFIS) was employed to design the thermal prediction model. In order to optimise the approach, a parametric study was carried out by changing the number of inputs and number of membership functions to the FCM-ANFIS model, and comparing the relative robustness of the designs. According to the results, the FCM-ANFIS model with four inputs and six membership functions achieves the best performance in terms of the accuracy of its predictive ability. The residual value of the model is smaller than ± 2 μm, which represents a 95% reduction in the thermally-induced error on the machine. Finally, the proposed method is shown to compare favourably against an Artificial Neural Network (ANN) model

Thermal error modelling of a gantry-type 5-axis machine tool using a Grey Neural Network Model

This paper presents a new modelling methodology for compensation of the thermal errors on a gantry-type 5-axis CNC machine tool. The method uses a “Grey Neural Network Model with Convolution Integral” (GNNMCI(1, N)), which makes full use of the similarities and complementarity between Grey system models and artificial neural networks (ANNs) to overcome the disadvantage of applying either model in isolation. A Particle Swarm Optimisation (PSO) algorithm is also employed to optimise the proposed Grey neural network. The size of the data pairs is crucial when the generation of data is a costly affair, since the machine downtime necessary to acquire the data is often considered prohibitive. Under such circumstances, optimisation of the number of data pairs used for training is of prime concern for calibrating a physical model or training a black-box model. A Grey Accumulated Generating Operation (AGO), which is a basis of the Grey system theory, is used to transform the original data to a monotonic series of data, which has less randomness than the original series of data. The choice of inputs to the thermal model is a non-trivial decision which is ultimately a compromise between the ability to obtain data that sufficiently correlates with the thermal distortion and the cost of implementation of the necessary feedback sensors. In this study, temperature measurement at key locations was supplemented by direct distortion measurement at accessible locations. This form of data fusion simplifies the modelling process, enhances the accuracy of the system and reduces the overall number of inputs to the model, since otherwise a much larger number of thermal sensors would be required to cover the entire structure. The Z-axis heating test, C-axis heating test, and the combined (helical) movement are considered in this work. The compensation values, calculated by the GNNMCI(1, N) model were sent to the controller for live error compensation. Test results show that a 85% reduction in thermal errors was achieved after compensation

The Application of ANN and ANFIS Prediction Models for Thermal Error Compensation on CNC Machine Tools

Thermal errors can have significant effects on Computer Numerical Control (CNC) machine tool accuracy. The errors come from thermal deformations of the machine elements caused by heat sources within the machine structure or from ambient temperature change. The effect of temperature can be reduced by error avoidance or numerical compensation. The performance of a thermal error compensation system essentially depends upon the accuracy and robustness of the thermal error model and its input measurements. This thesis first reviews different methods of designing thermal error models, before concentrating on employing Artificial Intelligence (AI) methods to design different thermal prediction models. In this research work the Adaptive Neuro-Fuzzy Inference System (ANFIS) is used as the backbone for thermal error modelling. The choice of inputs to the thermal model is a non-trivial decision which is ultimately a compromise between the ability to obtain data that sufficiently correlates with the thermal distortion and the cost of implementation of the necessary feedback sensors. In this thesis, temperature measurement was supplemented by direct distortion measurement at accessible locations. The location of temperature measurement must also provide a representative measurement of the change in temperature that will affect the machine structure. The number of sensors and their locations are not always intuitive and the time required to identify the optimal locations is often prohibitive, resulting in compromise and poor results. In this thesis, a new intelligent system for reducing thermal errors of machine tools using data obtained from thermography data is introduced. Different groups of key temperature points on a machine can be identified from thermal images using a novel schema based on a Grey system theory and Fuzzy C-Means (FCM) clustering method. This novel method simplifies the modelling process, enhances the accuracy of the system and reduces the overall number of inputs to the model, since otherwise a much larger number of thermal sensors would be required to cover the entire structure. An Adaptive Neuro-Fuzzy Inference System with Fuzzy C-Means clustering (ANFIS-FCM) is then employed to design the thermal prediction model. In order to optimise the approach, a parametric study is carried out by changing the number of inputs and number of Membership Functions (MFs) to the ANFIS-FCM model, and comparing the relative robustness of the designs. The proposed approach has been validated on three different machine tools under different operation conditions. Thus the proposed system has been shown to be robust to different internal heat sources, ambient changes and is easily extensible to other CNC machine tools. Finally, the proposed method is shown to compare favourably against alternative approaches such as an Artificial Neural Network (ANN) model and different Grey models

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

Skyrmion Gas Manipulation for Probabilistic Computing

The topologically protected magnetic spin configurations known as skyrmions offer promising applications due to their stability, mobility and localization. In this work, we emphasize how to leverage the thermally driven dynamics of an ensemble of such particles to perform computing tasks. We propose a device employing a skyrmion gas to reshuffle a random signal into an uncorrelated copy of itself. This is demonstrated by modelling the ensemble dynamics in a collective coordinate approach where skyrmion-skyrmion and skyrmion-boundary interactions are accounted for phenomenologically. Our numerical results are used to develop a proof-of-concept for an energy efficient ($\sim\mu\mathrm{W}$) device with a low area imprint ($\sim\mu\mathrm{m}^2$). Whereas its immediate application to stochastic computing circuit designs will be made apparent, we argue that its basic functionality, reminiscent of an integrate-and-fire neuron, qualifies it as a novel bio-inspired building block.Comment: 41 pages, 20 figure

Nanophotonic reservoir computing with photonic crystal cavities to generate periodic patterns

Reservoir computing (RC) is a technique in machine learning inspired by neural systems. RC has been used successfully to solve complex problems such as signal classification and signal generation. These systems are mainly implemented in software, and thereby they are limited in speed and power efficiency. Several optical and optoelectronic implementations have been demonstrated, in which the system has signals with an amplitude and phase. It is proven that these enrich the dynamics of the system, which is beneficial for the performance. In this paper, we introduce a novel optical architecture based on nanophotonic crystal cavities. This allows us to integrate many neurons on one chip, which, compared with other photonic solutions, closest resembles a classical neural network. Furthermore, the components are passive, which simplifies the design and reduces the power consumption. To assess the performance of this network, we train a photonic network to generate periodic patterns, using an alternative online learning rule called first-order reduced and corrected error. For this, we first train a classical hyperbolic tangent reservoir, but then we vary some of the properties to incorporate typical aspects of a photonics reservoir, such as the use of continuous-time versus discrete-time signals and the use of complex-valued versus real-valued signals. Then, the nanophotonic reservoir is simulated and we explore the role of relevant parameters such as the topology, the phases between the resonators, the number of nodes that are biased and the delay between the resonators. It is important that these parameters are chosen such that no strong self-oscillations occur. Finally, our results show that for a signal generation task a complex-valued, continuous-time nanophotonic reservoir outperforms a classical (i.e., discrete-time, real-valued) leaky hyperbolic tangent reservoir (normalized root-mean-square errors = 0.030 versus NRMSE = 0.127)

Applying Neural Network based on Fuzzy Cluster Pre-processing to Thermal Error Modeling for Coordinate Boring Machine

AbstractTo investigate the effect of the thermal characteristics of a motorized spindle system on the precision of a machine tool, a thermal error model for spindle axial expansion and radial thermal declination is proposed. With precision CNC coordinate boring machine as an object, using the five-point method to calibrate spindle system thermal errors by the eddy current sensors for axial thermal elongation and radial thermal tilted values, and temperatures of measurement points are obtained by the PT100. The relationships between the rotational speed and temperature field, thermal errors are analyzed. Then fuzzy clustering analysis method is used to group and optimize the temperature variables, selecting the variables for thermal error-sensitive. Finally the MIMO artificial neural network approach is established for the spindle axial thermal elongation and radial thermal drifts. The results indicated that the model prediction accuracy could reach 86% with perfect generalization ability under different cutting conditions, providing a theoretical model and thermal characteristic parameters for both thermal error compensation and thermal equilibrium design

Application of Soft Computing for the Prediction of Warpage of Plastic Injection

This paper deals with the development of accurate warpage prediction model for plastic injection molded parts using softcomputing tools namely, artificial neural networks and support vector machines. For training, validating and testing of thewarpage model, a number of MoldFlow (FE) analyses have been carried out using Taguchi’s orthogonal array in the designof experimental technique by considering the process parameters such as mold temperature, melt temperature, packing pressure,packing time and cooling time. The warpage values were found by analyses which were done by MoldFlow PlasticInsight (MPI) 5.0 software. The artificial neural network model and support vector machine regression model have beendeveloped using conjugate gradient learning algorithm and ANOVA kernel function respectively. The adequacy of the developedmodels is verified by using coefficient of determination. To judge the ability and efficiency of the models to predictthe warpage values absolute relative error has been used. The finite element results show, artificial neural network modelpredicts with high accuracy compared with support vector machine model

Memristors for the Curious Outsiders

We present both an overview and a perspective of recent experimental advances and proposed new approaches to performing computation using memristors. A memristor is a 2-terminal passive component with a dynamic resistance depending on an internal parameter. We provide an brief historical introduction, as well as an overview over the physical mechanism that lead to memristive behavior. This review is meant to guide nonpractitioners in the field of memristive circuits and their connection to machine learning and neural computation.Comment: Perpective paper for MDPI Technologies; 43 page