Volumetric Compensation System - AfM Technology · Company Contact Responsibility Assignment Objectives ... install the volumetric compensation system on SINUMERIK 840D ... AfM is

Volumetric Compensation System

Test Results for Zimmermann FZ 37

August 2008

Automation and Drives

Document Structure

General project implementation

Overview on VCS functionality by SIEMENS

Results of machine calibration by AfM Technology

Verification of VCS results by Zimmermann

Final Statement of Zimmermann


Siemens AG, DT MC MT

Frauenauracher Str. 80

91056 Erlangen

GERMANY

Responsibilitiy Assignment and Objectives

Company Contact Responsibility Assignment Objectives

Provide machine tool for

VCS test

Verify VCS results with

Zimmermann staff,

methods and equipment

Independently verify VCS

capabilities with own

staff

Provide Zimmermann

machine tools with VCS

for high accuracy

requests

Measurement of the

geometric errors of the

machine tool

Compilation of the VCS

file as input for geomet-

ric error correction by

Sinumerik 840D

Verify use of Laser

TRACER equipment for

measurement of the

geometric errors

Verify correctness of the

VCS file generated by

SW converter

Provide VCS Compile

Cycle

Installation of VCS

Compile Cycle on

Sinumerik 840D

User support

Proof correctness of the

VCS Compile Cycle SW

F. Zimmermann GmbH

Goethestraße 23

D-73770 Denkendorf

GERMANY

AfM Technology GmbH

Gartenstr. 133

73430 Aalen

GERMANY

www.afm-tec.de


IndependentMeasurements by Zimmermann

Procedure

Define LacerTRACER measurement strategy for FZ37 Geometric Error MeasurementGeneration of VCS File

CompensationNC-Part

Download VCS File in the NC:

Activate Sinumerik VCS functionality to compensate for the geometric machine error

Step 2Step 1 Step 3

Measurement of: Linear Positioning XTX YTY ZTZStraightness XTY XTZ YTX YTZ ZTX ZTYPitch XRY YRX ZRYYaw XRZ YRZ ZRXRoll XRX YRY ZRZSquareness XWY XWZ YWZ

//TRAC-CAL:SiemensVCS, Version: 1.5 , Build: 28 ,06-Feb-2008 18:32:40//[HEADER]MACHINE_PRODUCER = MACHINE_TYPE = FZ37MACHINE_NUMBER = CONTROL_PRODUCER = SIEMENSCONTROL_TYPE = 840DCONTROL_NUMBER = -CONTROL_SOFTWARE_VERSION = 6.5CUSTOMER = -OPERATOR = DATE = 09-FEB-2008 20:43:47TEMPERATURE = -COMMENT =

[CONFIGURATION]FILE_TYPE = VCSFILE_VERSION = 1.0AXIS_OFFSET_X = 0.0 AXIS_OFFSET_Y = 0.0 AXIS_OFFSET_Z = 0.0 LENGTH_UNIT [L_U] = MMANGLE_UNIT [A_U] = RADINTERPOLATION_BOUNDARY = 20KINEMATIC_TYPE = FXYZSQUARENESS_IS_POSITIVE = LARGER_THAN_90

[XTX]AXIS_LENGTH [L_U] = 4550.0 INTERVAL [L_U] = 50.00 DEVIATION [L_U]GRIDPOINTS = {

0.0 0.00000000000050.0 0.001240813924

100.0 0.002587210774150.0 0.004144773477

……….

VCS File

VCS Compile Cycle installed

Verify VCS Capabilities

Step 4LaserTRACER


Test Conditions

VCS requirements fulfilled by Zimmermann FZ37

Machine shows acceptable repeatability (standard laser

measurement acc. to ISO 230-2)

Machine shows acceptable linearity (standard circularity test

acc. to ISO 230-4)

Machine shows acceptable responsiveness for microsteps

Test environment

Influence of solar radiation

Ambient temperature varying by ± 2.5 °C

Machine boundary conditions

LEC for gantry axis remain active

CEC deactive

Suboptimal conditions

for optimal VCS results !!


Document Structure






Confidential

Industry SectorVolumetric Compensation System

2008-08-12 Slide 7/59

How to achieve positioning accuracy for a machine tool

Enhance already accurate machines with CNC based VCS compensation

Yesterday: Mechanical adjustment of

machine components and highly-

developed craftsmanship

TCP positioning errorM

an

ufa

ctu

rin

g e

ffo

rt

Today: Mechanical adjustment of

machine components and highly-

developed craftsmanship combined with

CNC based VCS compensation

CNC based

Compensation

VCS

Yesterday

“Scraping”

Today

“Programming”

Confidential


2008-08-12 Slide 8/59

Compensate for the Geometric Errors in a Machine Tool

Six errors for each linear axis plus three squareness errors(3-axes machine tool: 6 + 6 + 6 + 3 = 21 possible errors)

YawPitch

RollVertical Straightness

HorizontalStraightness

LinearPositioning

SquarenessX Y

Z

Note:

geometric

errors can

vary with

temperature

Confidential


2008-08-12 Slide 9/59

The 21 Geometric Errors of a 3-Axes Machine Toolresult in a Volumetric Error at the TCP

Note: There is displacement of the tool both in position and orientation

Resulting Volumetric Error

Programmed

tool orientation

Real

tool position

Z

YX

10

7

X 0

Y10

Z 7

Programmed

tool position

A 0

B 0

X 0.03

Y10.17

Z 6.95

Real

tool orientation

A 0.08

B -0.1Volumetric Error

Confidential


2008-08-12 Slide 10/59

Compensation of the Tool Center Point (TCP) and Orientation Error (5-axis capability of VCS)

5-axes Cartesian machine tools

Z

Y

Machine without Errors

C

A

Real Machine with Errors

No Compensation applied

VCS Compensation applied

VCS and Orientation

Compensation applied

TCP

Confidential


2008-08-12 Slide 11/59

Compensation of the Orientation Error in 5-Axes Machines

VCS and TRAORI must be switched on to enable interaction of VCS and TRAORIFor transformation types 24 and 40 only

Position of the TCP and orientation of the tool will be compensated

CNC based

Compensation

VCS

Linear Axes Errors Rotary Axes Errors

VCS

InputInput

TRAORI+

LEC

for Rotaries

Compensation of

Tool Center Point (TCP) position error and Tool orientation error

Confidential


2008-08-12 Slide 12/59

Responsibilities of the Partners –Typical workflow

VCS sales only to Machine tool builders or End users

Calibration service by Solution Partners

Machine Tool BuilderVCS Integration

VCS Installation

VCS Calibration

End Customer

Calibration

service

provider

Machine equipped

with VCS feature

Siemens sells the software options and documentation needed to

install the volumetric compensation system on SINUMERIK 840D

solution line (Calibration service not included)

SiemensVCS Compile Cycle

Sinumerik sl

AfM Technology

Sales of VCS Software

Calibration

service on

request

Calibration

service on

request

http://images.google.de/imgres?imgurl=http://www.datenambulanz.de/u/press_photo/CD_Rohling.jpg&imgrefurl=http://www.datenambulanz.de/cd&h=2212&w=2324&sz=1039&hl=de&start=1&tbnid=3XonnYQcMKBPWM:&tbnh=143&tbnw=150&prev=/images?q=cd&gbv=2&hl=de

Confidential


2008-08-12 Slide 13/59

VCS Experience Chain –step by step

Theory and Algorithmic

Integration in Automation

System

Approval in Machine Tool

System

Measurement

Techniques

Application Know-

How

Support

References

Siemens

VCS

Software

Sinumerik

based VCS

Machine

Tool

Builder

Scope o

f S

upply

of M

achin

e T

ool B

uild

er

Scope o

f S

upply

VCS off

VCS on


Document Structure






© Siemens AG 2008 - Änderungen vorbehalten

A&D MC MT P3Seite 15/18 14.03.2008Seite 15Wolfram Meyer LacerTracer-Measurement on machine tool

AfM Technology Group in Germany

AfM Technology GmbH

Headquarters

Gartenstr. 133

D-73430 Aalen

Fon +49 (0)7361 88 96 08-0

Fax +49 (0)7361 88 96 08-99

E-Mail [email protected]

www.afm-tec.de

AfM short hand for Accuracy for Machines

AfM is a Solution Partner of Siemens A&D

AfM Technology GmbH

Büro NürnbergAfM Technology GmbH

Office Nürnberg

AfM Technology GmbH

Headquarters Aalen

AfM Technology GmbH Ost

Subsidiary Burg

AfM Technology GmbH Ost

Subsidiary Burg

Johann-Sebastian-Bach-Str. 60

D-39288 Burg

Fon +49 (0)3921 63 63 9-0

Fax +49 (0)3921 63 63 9-29

E-Mail: [email protected]

AfM Technology GmbH

Office Nürnberg

Eulenholz 8

D-90518 Altdorf

Fon +49 (0)9187 90 69 580

Fax +49 (0)9187 90 69 579

E-Mail: [email protected]

mailto:[email protected]








LaserTRACER measurement equipment

developed, especially for calibration of coordinate measuring

machines (CMM) and machine tools

full error mapping, based on pure length measurements

automatic tracking interferometer

resolution: 1 nm

accuracy: 0,2 µm + 0,3 µm/m

measurement range: 15 m

(unlimited by mathematical superposition)


A&D MC MT P3Seite 17/18 14.03.2008

17Seite 17Wolfram Meyer LacerTracer-Measurement on machine tool

Volumetric Calibration

Mount the cat eye on the

machine spindle

Setup the LaserTRACER on

4-6 positions in the machine

volume. An excact alignment

of the LaserTRACER is not

necessary

Download the CNC programs

in the control

Automatically measurement

of the LaserTRACER during

stand still of machine tool, or

by trigger signal

Measurement time approx. 1 h

per position



Calculation of geometric deviations

Calculation of all 21 geometric deviations by multilateration method (similar to GPS)

Output of an error map as a file in SINUMERIK VCS format

Generation of measurement report

VCS File Format

[XTX]

AXIS_LENGTH [mm] = 1800

LINEAR_CORRECTION [mm/m] = 0.0

INTERVAL [mm] = 25

DEVIATION [mm]

GRIDPOINTS = {

-75.0 -0.012193623479

-50.0 0.000000000000

-25.0 0.012193623479

0.0 0.018671152358

25.0 0.016196874983

50.0 0.011456611499

75.0 0.011674987082

Straightness deviation:

Measurement report from february, 2008

customer: F. Zimmermann GmbH

location: Denkendorf

device type: FZ37

(examplary data)


A&D MC MT P3Seite 19/18 14.03.2008Seite 19Wolfram Meyer

Volumetric Compensation and Verification

VCS File Format

[XTX]

AXIS_LENGTH [mm] = 1800

LINEAR_CORRECTION [mm/m] = 0.0

INTERVAL [mm] = 25

DEVIATION [mm]

GRIDPOINTS = {

-75.0 -0.012193623479

-50.0 0.000000000000

-25.0 0.012193623479

0.0 0.018671152358

25.0 0.016196874983

50.0 0.011456611499

75.0 0.011674987082

Compensation data + SINUMERIK with VCS = higher accuracy

Installaion of error map for VCS-Option in the control

Measurement of residual error map and/or acceptance test according ISO 230 with

LaserTracer

Verification with ballbar, standard laser interferometer, etc.

LacerTracer-Measurement on machine tool



LaserTRACER measurement of the FZ37

X=0

Y=0

Z=0

X

Z

Y

The results on the following pages are related to the reference point shown below




Positioning error of the X-Axis


XTX


A&D MC MT P3Seite 22/18 14.03.2008

Positioning error of the Y-Axis

Seite 22Wolfram Meyer LacerTracer-Measurement on machine tool

-1500.0

YTY


A&D MC MT P3Seite 23/18 14.03.2008

Positioning error of the Z-Axis


-1500.0

ZTZ


A&D MC MT P3Seite 24/18 14.03.2008

Straightness error of the X-Axis


XTY

XTZ


A&D MC MT P3Seite 25/18 14.03.2008

Straightness error of the Y-Axis


YTX

YTZ

-1500.0

-1500.0


A&D MC MT P3Seite 26/18 14.03.2008

Straightness error of the Z-Axis


ZTX

ZTY

-1500.0

-1500.0


A&D MC MT P3Seite 27/18 14.03.2008

Yaw-, Pitch- and Roll- Error


-1500.0

-1500.0-1500.0 -1500.0

-1500.0

-1500.0

XRX XRY XRZ

YRX YRY YRZ

ZRX ZRY ZRZ


Document Structure






Siemens VCS Verification / Feb. 2008

The FZ37 Portal Milling Machine

Linear Axis

X = 3.000 – 40.000mm (Rack and Pinion Drive)

Y = 2.500 – 5.000mm (Rack and Pinion Drive)

Z = 1.000 – 2.500mm (Ball Screw Drive / alt. Rack and Pinion Drive)

Speed: Up to 50m/min.

Acceleration: Up to 5m/s2

Milling Head VH 2

A-axis: +/- 110°

C-axis: +/- 275 / 360°

Speed (Alc) up to: 90°/s

A-/ C-axis clamped / controlled

Torque A/C: 800 Nm (controlled)

Milling Spindle

45 kW, 67 Nm

25.000 min-1

HSK 63 A

Vibration sensor

Temperature sensor (Bearing)

Automatic Grease Lubrication

Milling Head VH3

A-axis: +/- 110°

C-axis: +/- 275 / 360°

Speed (Alc) up to: 90°/s

A-/ C-Axis clamped / controlled

Torque A/C: 1.000 Nm (controlled)

Machine Bed

Quality: DIN 876/II

Load capacity: 30.000 kg/m2

Side Walls

Welded steed construction filled up with a special concrete-composite.

Milling Spindle

60 kW, 95 Nm

22.000 min-1

HSK 63 A

Vibration sensor

Temperature sensor (Bearing)

Automatic Grease Lubrication


Verification Tests

In order to verify the VCS results Zimmermann quality

control department performed the following tests:

Linear Positioning Behaviour with Renishaw ML10

Straightness Measurement with Raytec Gepard

Circularity Tests with Renishaw Ball Bar QC10

Inclination Measurement with Wyler Blue Level


Linear Positioning of the X-Axis

X

X

X

Position 1

Position 2

Position 3


Linear Positioning of the X-Axis

Position 1

-36%

Position 2

-55%

Position 3

-66%

VCS off VCS off

VCS off

VCS onVCS on

VCS on

Comment:

Temperature conditions changed

between initial VCS set-up and

VCS verification measurement

XTX XTX

XTX


Straightness Measurement of the X-Axis

VCS on

-74%

VCS off

VCS on

-62%

VCS offXTY

XTZ


Linear Positioning of the Y-Axis

Position 1

Position 2

Y

Y


Linear Positioning of the Y-Axis

Comment:

Temperature conditions changed

between initial VCS set-up and

VCS verification measurement

Position 1

-76%

Position 2

-42%

VCS off

VCS offVCS on

VCS on

YTY YTY

Caution:

Position error in Position 1 is negativ

Position error in Position 2 is positiv


Straightness Measurement of the Y-Axis

VCS on

-62%

VCS off

VCS on

-38%

VCS off

YTX

YTZ


Circularity Tests

Position 1:

x-y-Plane

Position 2:

y-z-Plane


Circularity Tests

Position 1: x-y-Plane

Improvement of Circularity: -36%

Improvement of Squareness: -94%

VCS off VCS on


Circularity Tests

Position 2: y-z-Plane

Improvement of Circularity: -48%

Improvement of Squareness: -58%

VCS off VCS on


VCS Orientation Compensation

Wyler

Blue LevelPosition 1:

C=0 A=90

Position 2:

C=90 A=90


VCS Orientation CompensationPosition 1: C=0 A=90

Y

X=0 Z=0 X=0 Z=-750

-1500 -1000 -500 0 500 1000 1500

Y

Ori

en

tati

on

err

or

-1500 -1000 -500 0 500 1000 1500

Y

Ori

en

tati

on

err

or

X=0 Z=-1500

Ori

en

tati

on

err

or

VCS off

VCS on

-75%

VCS off

VCS on

-80%

-1500 -1000 -500 0 500 1000 1500

VCS off

VCS on

-84%


VCS Orientation CompensationPosition 1: C=90 A=90

X=0 Z=-1500

X

X=0 Z=0 X=0 Z=-750 O

rien

tati

on

err

or

Ori

en

tati

on

err

or

VCS off

VCS on

-75%

VCS off

VCS on

-80%

0 500 1000 1500 2000 2500 3000 3500 4000 4500

VCS off

VCS on

-76%

0 500 1000 1500 2000 2500 3000 3500 4000 4500

X

VCS off

VCS on

-72%

0 500 1000 1500 2000 2500 3000 3500 4000 4500

X

Ori

en

tati

on

err

or

VCS off

VCS on

-68%


Document Structure







VCS Summary

Documents

Volumetric Compensation System - AfM Technology · Company Contact Responsibility Assignment Objectives ... install the volumetric compensation system on SINUMERIK 840D ... AfM is