Towards an integrated strategy for effective machine tool probing

Spindle-mounted probing systems on machine tools have become commonplace within manufacturing industry over the last ten years. On-machine probing (OMP) is often used as an automatic way of finding workpiece offsets on machine tools to allow better repeatability and more automated procedures. In more advanced engineering OMP may be used for in-process gauging, error correction or even final pass-off. They therefore form part of the measurement process that defines the overall quality control chain. When used in production the probing system, and the machine that carries them, is subjected to harsh and variable conditions that are not experienced in a metrology room. This includes undergoing tool change routines, being affected by changing thermal conditions and contaminated by cutting debris. Unlike a traceable quality control department there is also the possibility of comparatively poor calibration techniques as this is considered a machine tool function. As a result, many companies do not use their OMP effectively, either because of a lack of understanding of capability or mistrust in the results due to a lack of understanding of uncertainties. This research has provided the building blocks for a “bottom up” strategy to analyse influencing factors for OMP to enable end users to get reliable results with the lowest uncertainty for the desired function. Crucially, the research assumes different tolerance requirements for various functions that can be performed with such a probing system in order to avoid recommending onerous pre-requisite procedures where they are not needed. The influencing factors for OMP are identified through literature review and a failure mode analysis conducted with experts from industry and academia. The magnitudes of the key factors and effects are then analysed through stated system specifications or experimentation on example machines. However, the dissertation concluded that all machine tools behave differently, and have different accuracy requirements. The main outcome of this work is, therefore, to determine which tests and checks are pre-requisite for OMP on any machine, depending upon their intended use. Ultimately, though, the work concludes that the unpredictability of thermal behaviour is likely to cause the greatest problems for on-machine probing, with a full understanding being required for reproducibility of measurement results from a machine tool

Conference on Thermal Issues in Machine Tools: Proceedings

Inhomogeneous and changing temperature distributions in machine tools lead to sometimes considerable quality problems in the manufacturing process. In addition, the switching on and off of aggregates, for example, leads to further fluctuations in the temperature field of machine tools. More than 100 specialists discussed these and other topics from the field of thermal research at the 1st Conference on Termal Issues in Machine Tools in Dresden from 22 to 23 March.:Efficient modelling and computation of structure-variable thermal behavior of machine tools S. Schroeder, A. Galant, B. Kauschinger, M. Beitelschmidt Parameter identification software for various thermal model types B. Hensel, S. Schroeder, K. Kabitzsch Minimising thermal error issues on turning centre M. Mareš, O. Horejš, J. Hornych The methods for controlled thermal deformations in machine tools A. P. Kuznetsov, H.-J. Koriath, A.O. Dorozhko Efficient FE-modelling of the thermo-elastic behaviour of a machine tool slide in lightweight design C. Peukert, J. Müller, M. Merx, A. Galant, A. Fickert, B. Zhou, S. Städtler, S. Ihlenfeldt, M. Beitelschmidt Development of a dynamic model for simulation of a thermoelectric self-cooling system for linear direct drives in machine tools E. Uhlmann, L. Prasol, S.Thom, S. Salein, R. Wiese System modelling and control concepts of different cooling system structures for machine tools J. Popken, L. Shabi, J. Weber, J. Weber The electric drive as a thermo-energetic black box S. Winkler, R. Werner Thermal error compensation on linear direct drive based on latent heat storage I. Voigt, S. Winkler, R. Werner, A. Bucht, W.-G. Drossel Industrial relevance and causes of thermal issues in machine tools M. Putz, C. Richter, J. Regel, M. Bräunig Clustering by optimal subsets to describe environment interdependencies J. Glänzel, R. Unger, S. Ihlenfeldt Using meta models for enclosures in machine tools F. Pavliček, D. P. Pamies, J. Mayr, S. Züst, P. Blaser, P. Hernández-Becerro, K. Wegener Model order reduction of thermal models of machine tools with varying boundary conditions P. Hernández-Becerro, J. Mayr, P. Blaser, F. Pavliček, K. Wegener Effectiveness of modelling the thermal behaviour of the ball screw unit with moving heat sources taken into account J. Jedrzejewski, Z. Kowal, W. Kwasny, Z. Winiarski Analyzing and optimizing the fluidic tempering of machine tool frames A. Hellmich, J. Glänzel, A. Pierer Thermo-mechanical interactions in hot stamping L. Penter, N. Pierschel Experimental analysis of the heat flux into the grinding tool in creep feed grinding with CBN abrasives C. Wrobel, D. Trauth, P. Mattfeld, F. Klocke Development of multidimensional characteristic diagrams for the real-time correction of thermally caused TCP-displacements in precise machining M. Putz, C. Oppermann, M. Bräunig Measurement of near cutting edge temperatures in the single point diamond turning process E. Uhlmann, D. Oberschmidt, S. Frenzel, J. Polte Investigation of heat flows during the milling processes through infrared thermography and inverse modelling T. Helmig, T. Augspurger, Y. Frekers, B. Döbbeler, F. Klocke, R. Kneer Thermally induced displacements of machine tool structure, tool and workpiece due to cutting processes O. Horejš, M. Mareš, J. Hornych A new calibration approach for a grey-box model for thermal error compensation of a C-Axis C. Brecher, R. Spierling, M. Fey Investigation of passive torque of oil-air lubricated angular contact ball bearing and its modelling J. Kekula, M. Sulitka, P. Kolář, P. Kohút, J. Shim, C. H. Park, J. Hwang Cooling strategy for motorized spindle based on energy and power criterion to reduce thermal errors S. Grama, A. N. Badhe, A. Mathur Cooling potential of heat pipes and heat exchangers within a machine tool spindleo B. Denkena, B. Bergman, H. Klemme, D. Dahlmann Structure model based correction of machine tools X. Thiem, B. Kauschinger, S. Ihlenfeldt Optimal temperature probe location for the compensation of transient thermal errors G. Aguirre, J. Cilla, J. Otaegi, H. Urreta Adaptive learning control for thermal error compensation on 5-axis machine tools with sudden boundary condition changes P. Blaser, J. Mayr, F. Pavliček, P. Hernández-Becerro, K. Wegener Hybrid correction of thermal errors using temperature and deformation sensors C. Naumann, C. Brecher, C. Baum, F. Tzanetos, S. Ihlenfeldt, M. Putz Optimal sensor placement based on model order reduction P. Benner, R. Herzog, N. Lang, I. Riedel, J. Saak Workpiece temperature measurement and stabilization prior to dimensional measurement N. S. Mian, S. Fletcher, A. P. Longstaff Measurement of test pieces for thermal induced displacements on milling machines H. Höfer, H. Wiemer Model reduction for thermally induced deformation compensation of metrology frames J. v. d. Boom Local heat transfer measurement A. Kuntze, S. Odenbach, W. Uffrecht Thermal error compensation of 5-axis machine tools using a staggered modelling approach J. Mayr, T. Tiberini. P. Blaser, K. Wegener Design of a Photogrammetric Measurement System for Displacement and Deformation on Machine Tools M. Riedel, J. Deutsch, J. Müller. S. Ihlenfeldt Thermography on Machine Tools M. Riedel, J. Deutsch, J. Müller, S. Ihlenfeldt Test piece for thermal investigations of 5-axis machine tolls by on-machine measurement M. Wiesener. P. Blaser, S. Böhl, J. Mayr, K. Wegene

Kinematics and Robot Design II (KaRD2019) and III (KaRD2020)

This volume collects papers published in two Special Issues “Kinematics and Robot Design II, KaRD2019” (https://www.mdpi.com/journal/robotics/special_issues/KRD2019) and “Kinematics and Robot Design III, KaRD2020” (https://www.mdpi.com/journal/robotics/special_issues/KaRD2020), which are the second and third issues of the KaRD Special Issue series hosted by the open access journal robotics.The KaRD series is an open environment where researchers present their works and discuss all topics focused on the many aspects that involve kinematics in the design of robotic/automatic systems. It aims at being an established reference for researchers in the field as other serial international conferences/publications are. Even though the KaRD series publishes one Special Issue per year, all the received papers are peer-reviewed as soon as they are submitted and, if accepted, they are immediately published in MDPI Robotics. Kinematics is so intimately related to the design of robotic/automatic systems that the admitted topics of the KaRD series practically cover all the subjects normally present in well-established international conferences on “mechanisms and robotics”.KaRD2019 together with KaRD2020 received 22 papers and, after the peer-review process, accepted only 17 papers. The accepted papers cover problems related to theoretical/computational kinematics, to biomedical engineering and to other design/applicative aspects

Development of an augmented reality guided computer assisted orthopaedic surgery system

Previously held under moratorium from 1st December 2016 until 1st December 2021.This body of work documents the developed of a proof of concept augmented reality guided computer assisted orthopaedic surgery system – ARgCAOS. After initial investigation a visible-spectrum single camera tool-mounted tracking system based upon fiducial planar markers was implemented. The use of visible-spectrum cameras, as opposed to the infra-red cameras typically used by surgical tracking systems, allowed the captured image to be streamed to a display in an intelligible fashion. The tracking information defined the location of physical objects relative to the camera. Therefore, this information allowed virtual models to be overlaid onto the camera image. This produced a convincing augmented experience, whereby the virtual objects appeared to be within the physical world, moving with both the camera and markers as expected of physical objects. Analysis of the first generation system identified both accuracy and graphical inadequacies, prompting the development of a second generation system. This too was based upon a tool-mounted fiducial marker system, and improved performance to near-millimetre probing accuracy. A resection system was incorporated into the system, and utilising the tracking information controlled resection was performed, producing sub-millimetre accuracies. Several complications resulted from the tool-mounted approach. Therefore, a third generation system was developed. This final generation deployed a stereoscopic visible-spectrum camera system affixed to a head-mounted display worn by the user. The system allowed the augmentation of the natural view of the user, providing convincing and immersive three dimensional augmented guidance, with probing and resection accuracies of 0.55±0.04 and 0.34±0.04 mm, respectively.This body of work documents the developed of a proof of concept augmented reality guided computer assisted orthopaedic surgery system – ARgCAOS. After initial investigation a visible-spectrum single camera tool-mounted tracking system based upon fiducial planar markers was implemented. The use of visible-spectrum cameras, as opposed to the infra-red cameras typically used by surgical tracking systems, allowed the captured image to be streamed to a display in an intelligible fashion. The tracking information defined the location of physical objects relative to the camera. Therefore, this information allowed virtual models to be overlaid onto the camera image. This produced a convincing augmented experience, whereby the virtual objects appeared to be within the physical world, moving with both the camera and markers as expected of physical objects. Analysis of the first generation system identified both accuracy and graphical inadequacies, prompting the development of a second generation system. This too was based upon a tool-mounted fiducial marker system, and improved performance to near-millimetre probing accuracy. A resection system was incorporated into the system, and utilising the tracking information controlled resection was performed, producing sub-millimetre accuracies. Several complications resulted from the tool-mounted approach. Therefore, a third generation system was developed. This final generation deployed a stereoscopic visible-spectrum camera system affixed to a head-mounted display worn by the user. The system allowed the augmentation of the natural view of the user, providing convincing and immersive three dimensional augmented guidance, with probing and resection accuracies of 0.55±0.04 and 0.34±0.04 mm, respectively

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808

Book of Abstracts 15th International Symposium on Computer Methods in Biomechanics and Biomedical Engineering and 3rd Conference on Imaging and Visualization

In this edition, the two events will run together as a single conference, highlighting the strong connection with the Taylor & Francis journals: Computer Methods in Biomechanics and Biomedical Engineering (John Middleton and Christopher Jacobs, Eds.) and Computer Methods in Biomechanics and Biomedical Engineering: Imaging and Visualization (JoãoManuel R.S. Tavares, Ed.). The conference has become a major international meeting on computational biomechanics, imaging andvisualization. In this edition, the main program includes 212 presentations. In addition, sixteen renowned researchers will give plenary keynotes, addressing current challenges in computational biomechanics and biomedical imaging. In Lisbon, for the first time, a session dedicated to award the winner of the Best Paper in CMBBE Journal will take place. We believe that CMBBE2018 will have a strong impact on the development of computational biomechanics and biomedical imaging and visualization, identifying emerging areas of research and promoting the collaboration and networking between participants. This impact is evidenced through the well-known research groups, commercial companies and scientific organizations, who continue to support and sponsor the CMBBE meeting series. In fact, the conference is enriched with five workshops on specific scientific topics and commercial software.info:eu-repo/semantics/draf