Development of an error compensation case study for 3D printers

The paper developed presents a case study that allows students to learn an easy way to improve the accuracy of low cost 3D printers. The document detailed a methodology to achieve this goal. First, it is necessary to print an initial CAD design. A commercial scanner is calibrated and the pieces are scanned to obtain the different errors. Then, a program is generated to compensate the code numerical control of the printer. This fact allows students to print a new piece having less errors than before, which it involves improve the printer accuracy

Modelling, kinematic parameter identification and sensitivity analysis of a Laser Tracker having the beam source in the rotating head

This paper presents a new kinematic model, a parameter identification procedure and a sensitivity analysis of a laser tracker having the beam source in the rotating head. This model obtains the kinematic parameters by the coordinate transformation between successive reference systems following the Denavit–Hartenberg method. One of the disadvantages of laser tracker systems is that the end-user cannot know when the laser tracker is working in a suitable way or when it needs an error correction. The ASME B89.4.19 Standard provides some ranging tests to evaluate the laser tracker performance but these tests take a lot of time and require specialized equipment. Another problem is that the end-user cannot apply the manufacturer’s model because he cannot measure physical errors. In this paper, first the laser tracker kinematic model has been developed and validated with a generator of synthetic measurements using different meshes with synthetic reflector coordinates and known error parameters. Second, the laser tracker has been calibrated with experimental data using the measurements obtained by a coordinate measuring machine as nominal values for different strategies, increasing considerably the laser tracker accuracy. Finally, a sensitivity analysis of the length measurement system tests is presented to recommend the more suitable positions to perform the calibration procedure

Improving the Accuracy of a Machine Tool with Three Linear Axes using a Laser Tracker as Measurement System

This paper presents a real way to improve machine tool accuracy using interferometry techniques based on laser tracker as measurement system. This is based on an indirect measurement of the geometric error of the MT; characterizing their combined effect though volumetric verification. This technique can be used to verify all types of machine through its kinematic model, relating measured points with the laser tracker and nominal points. Using non-lineal optimization techniques the difference between pair of points are reduced. Finally, it provides the approximation functions of the machine tool geometric errors used to compensate theirs influence on MT accuracy. As it is a mathematical compensation result of an optimization procedure, the improvement on MT accuracy should be validate using the same or external measurement system. This paper shows that volumetric verification provides an real improvement of the MT accuracy

Effect of ambient temperature on machine tool compensation functions

Volumetric verification is increasing daily its relevance. However, as it is based on mathematical compensation, it does not model only the influence of the machine tool's geometric error to verify, but the total error of the data. Among all error sources, thermal variations due to changes in environmental conditions strongly affect MT position accuracy. This paper studies how verification changes affect compensation functions based on a modification of machine tool kinematic model and a generator of synthetic data. It takes into consideration the influence of the measurement noise on verification too. Moreover, the paper also studies how differences between verification and working conditions affect the accuracy of MT compensation functions. To do that, a brief explanation of the developed algorithm is presented

Education Software for the Modelling and Calibration of Kinematic Mechanisms

AbstractThis paper presents a new software for teaching the most important aspects of modelling, characterization and calibration of parallel mechanisms by means of the kinematic model, the kinematic parameter identification and the control of the system actuators and sensors. This application allows the student to develop competencies such as analysis and synthesis, to solve problems, research skills and to apply their knowledge.The developed tool presents a special interest in areas such as education, industry and research, since the application interface allows the user to carry out the different steps of the calibration procedure in an easy way. Besides, only one application is necessary to perform all the procedure for data acquisition and kinematic parameter identification.Moreover, thanks to the flexibility that the developed software offers in the programming, a senior undergraduate student can modify different algorithm variables and analyze the effects that take place with these changes. This application therefore presents an important utility as a teaching tool for the learning process and analysis of the different steps in the parallel mechanism optimization

Preliminary study of Augmented Reality based manufacturing for further integration of Quality Control 4.0 supported by metrology

Augmented Reality (AR) is a key technology enabling Industry 4.0, which enriches human perspectives by overlaying digital information onto the real world. The maturity of AR technology has grown recently. As processes in the automotive and aeronautic sectors require high quality and near-zero error rates to ensure the safety of end-users, AR can be implemented to facilitate workers with immersive interfaces to enhance productivity, accuracy and autonomy in the quality sector. In order to analyse whether there is a real and growing interest in the use of AR as assisting technology for manufacturing sector in general and quality control in particular, two specific research questions are defined. In addition, two well-known research databases (Scopus, Web of Science) are used for the paper selection phase in accordance with the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) methodology to conduct a preliminary study and evaluate the current development of AR applications in manufacturing sector in order to answer the defined questions. It is found that while the development of AR technology has widely implemented to assign real-time information to several systems and processes in assembly and maintenance sectors, this tendency has only emerged in the quality sector over the last few years. However, AR-based quality control has proved its advantages in improving productivity, accuracy and precision of operators as well as benefits to manufacturing in terms of product and process quality control across different manufacturing phases

Application of virtual distances methodology to laser tracker verification with an indexed metrology platform

High-range measuring equipment like laser trackers need large dimension calibrated reference artifacts in their calibration and verification procedures. In this paper, a new verification procedure for portable coordinate measuring instruments based on the generation and evaluation of virtual distances with an indexed metrology platform is developed. This methodology enables the definition of an unlimited number of reference distances without materializing them in a physical gauge to be used as a reference. The generation of the virtual points and reference lengths derived is linked to the concept of the indexed metrology platform and the knowledge of the relative position and orientation of its upper and lower platforms with high accuracy. It is the measuring instrument together with the indexed metrology platform one that remains still, rotating the virtual mesh around them. As a first step, the virtual distances technique is applied to a laser tracker in this work. The experimental verification procedure of the laser tracker with virtual distances is simulated and further compared with the conventional verification procedure of the laser tracker with the indexed metrology platform. The results obtained in terms of volumetric performance of the laser tracker proved the suitability of the virtual distances methodology in calibration and verification procedures for portable coordinate measuring instruments, broadening and expanding the possibilities for the definition of reference distances in these procedures

Identification and Kinematic Calculation of Laser Tracker Errors

AbstractCalibration of Laser Tracker systems is based most times in the determination of its geometrical errors. Some standards as the ASME B89.4.19 (2006) and the VDI 2617-10 (2011) describe different tests to calculate the geometric misalignments that cause systematic errors in Laser Tracker measurements. These errors are caused not only because of geometrical misalignments and other sources of error must also be taken in count. In this work we want to express the errors in a kinematic form. Errors will be split in two different components, geometric and kinematic errors. The first ones depend on the offsets, tilts and eccentricity of the mechanical and optical components of the system. Kinematic errors are different for every position of the Laser tracker, so they must be formulated as functions of three system variables: range (R), vertical angle (V) and horizontal angle (H). The goal of this work is to set up an evaluation procedure to determine geometric and kinematic errors of Laser Trackers

Virtual distances methodology as verification technique for AACMMs with a capacitive sensor based indexed metrology platform

This paper presents a new verification procedure for articulated arm coordinate measuring machines (AACMMs) together with a capacitive sensor-based indexed metrology platform (IMP) based on the generation of virtual reference distances. The novelty of this procedure lays on the possibility of creating virtual points, virtual gauges and virtual distances through the indexed metrology platform’s mathematical model taking as a reference the measurements of a ball bar gauge located in a fixed position of the instrument’s working volume. The measurements are carried out with the AACMM assembled on the IMP from the six rotating positions of the platform. In this way, an unlimited number and types of reference distances could be created without the need of using a physical gauge, therefore optimizing the testing time, the number of gauge positions and the space needed in the calibration and verification procedures. Four evaluation methods are presented to assess the volumetric performance of the AACMM. The results obtained proved the suitability of the virtual distances methodology as an alternative procedure for verification of AACMMs using the indexed metrology platform

A review of tangential composite and radial composite gear inspection

This paper presents an overview of the literature on tangential composite and radial composite gear inspection. It demonstrates – by dealing with their origins and key milestones in their history and development – the important role that inspections play in terms of the functional nature of the gears concerned. This comprehensive consideration of the subject also attempts to demonstrate how the lack of clear guidelines and standards designed to unify the criteria applied to testing, the interpretation of results and calibration of equipment, along with the number of simultaneous variables involved in trials of this type, leads to doubts (including with respect to the actual standards concerned) as to whether these tests are valid, or instead accepted only has partial validations. Even so, the repeatability of the experimental data demonstrates not only their metrological potential, with respect to functionality, but also the fact that they are both effective and origina