Simple and simultaneous measurement of five-degrees-of-freedom error motions of high-speed microspindle: Error analysis

We have developed a simple and low-cost optical measurement system for the simultaneous measurement of the five-degrees-of-freedom error motions of high-speed microspindles. We demonstrated the usefulness of the system by using it to measure actual spindle rotation errors, and analyzed the major error factors. First, the measurement error due to the form error of the lens was analyzed by ray tracing. Second, we analyzed the measurement error due to a displacement of an irradiation laser point on a 3 mm diameter ball lens. Furthermore, we investigated the effect of the centrifugal force and the crosstalk problem of multiple laser beams. The results indicated that a form error of the rod lens significantly affected the measurement accuracy and that a change in the laser beam irradiation point of the ball lens due to a radial displacement had no significant effect on the measurement accuracy. Finally, we confirmed that, owing to the centrifugal force, the measurement accuracy decreased as the speed of rotation increased, and that there was no crosstalk that the reflected and transmitted laser beams in the X direction were detected by the photodiode in the Y direction for displacements within −10 to 10 μm.     

同轴度测量误差的分析与探讨

详细分析测量同轴度误差的近似计算方法的误差规律及其影响因素,指出测量同轴度误差的合理及不合理的采样位置,为同轴度误差测量过程中的数据采样提供依据。     

Modeling and error analysis for assessing spindle radial error motions

The rotating accuracy of a machine tool spindle directly affects the roundness of machined parts. Commonly, a precision arbor and one or two probes are used to inspect the spindle axis error motion. When the spindle error motion is in the same order of magnitude as the accuracy of the reference arbor, it is desirable to separate the roundness error of the reference arbor from the spindle error. One of the methods used is the three-probe method. This paper presents an exact geometric model and error analysis for the conventional three-probe method. The exact model is used to show that there is an approximation error in the commonly used governing equations of the three-probe method. To reduce inaccuracy in the converted axis motion and arbor contour, the reference arbor accuracy should be at least ten times better than that of the axis motion. It is also shown that the mounting error of the probes should be less than one-fiftieth of the size of the axis motion and the arbor size. The exact geometric model developed in this paper can also be extended to analyze the accuracy of other spindle inspection or roundness measurement methods.     

Zone-plate inteferometer to measure the positioning error of a cutting tool

A simple type of zone-plate interferometer has been developed to measure precisely the positioning error of a cutting tool. Interference fringes obtained by the interferometer are little affected by air turbulence in the optical paths and by machine vibrations. The shape of the mirrors surface being tested is spherical and is manufactured with an ultraprecision lathe. A zone plate is set at the midposition between the vertex of the spherical mirror being tested and the center of curvature of the mirror. The error in the shape of the mirror and the positioning error of the tool can be determined by analyzing the interference fringes. Two spherical concave mirrors were measured. One mirror was manufactured with a tool that had same positioning error. The positioning error was observed as distortion of the interference fringes. The images obtained by the zone-plane interferometer agree well with the images obtained by a Fizeau interferometer and a computer simulation based on the experimental results. The other mirror was manufactured with the tool after the positioning error had been eliminated, based upon the results of the above experiments. The interference fringes of the mirror show no distortion, and the error in the shape of the mirror is small.     

同轴度误差测量方法分析

详细分析测量同轴度误差的“刃口状V形架测量方法”的原理,明确测量装置读数的规律及特征,指出GB1958-80中有关内容的不足,提出测量同轴度误差的“刃口状V形架测量方法”的正确方法、步骤及计算过程。     

The design of a five-degree-of-freedom powered orthosis for the upper limb.

In response to the need for a sophisticated powered upper-limb orthosis for use by people with disabilities and/or limb weakness or injury, the MULOS (motorized upper-limb orthotic system) has been developed. This is a five-degree-of-freedom electrically powered device having three degrees of freedom at the shoulder, one at the elbow and one to provide pronation/supination. The shoulder mechanism consists of a serial linkage having an equivalent centre of rotation close to that of the anatomical shoulder; this is a self-contained module in which power transmission is provided by tensioned cables. The elbow and pronation/supination modules are also self-contained. The system has been designed to operate under three modes of control: 1. As an assistive robot attached directly to the arm to provide controlled movements for people with severe disability. In this case, it can be operated by a variety of control interfaces, including a specially designed five-degree-of-freedom joystick. 2. Continuous passive motion for the therapy of joints after injury. The trajectory of the joints is selected by 'walk-through' programming and can be replayed for a given number of cycles at a chosen speed. 3. As an exercise device to provide strengthening exercises for elderly people or those recovering from injury or surgery. This mode has not been fully implemented at this stage. In assistive mode, prototype testing has demonstrated that the system can provide the movements required for a range of simple tasks and, in continuous passive motion (CPM) mode, the programming system has been successfully implemented. Great attention has been paid to all aspects of safety. Future work is required to identify problems of operation, and to develop new control interfaces.     

Measurement of multi-degree-of-freedom error motions of a precision linear air-bearing stage

This paper describes the measurement of straightness error motions (vertical straightness and horizontal straightness) and rotational error motions (pitch, yaw and roll) of a commercial precision linear air-bearing stage actuated by a linear motor. Each of the error motions was measured by two different methods for assurance of reliability. The stage was placed in the XY-plane and moved along the X-direction. The pitch error and yaw error, which were measured by an autocollimator and the angle measurement kit of a laser interferometer, were about 8.7 and 1.6 arc-s, respectively, over a travel of 150 mm with a moving speed of 10 mm/s. The roll error was measured by the autocollimator through scanning a flat mirror along the X-direction. The second method for roll error measurement was to scan two capacitance-type displacement probes along the flat surface placed in the XZ-plane. The two probes with their sensing axes in the Y-direction were aligned with a certain spacing along the Z-axis. The roll error can be obtained by dividing the difference of the outputs of the two probes by the spacing between the two probes. The roll error was measured to be approximately 11.8 arc-s over the 150 mm travel. The horizontal straightness error and the vertical straightness error (Y- and Z-straightness errors) were measured by using the straightness measurement kit of the laser interferometer. The second method for straightness measurement was to scan the flat surface with a capacitance-type displacement probe. The horizontal and vertical straightness errors of the stage over the 150 mm travel were measured to be approximately 207 and 660 nm, respectively.     

Measurement and compensation of error motions of a diamond turning machine

This paper describes the measurement and compensation of error motions of a diamond turning machine for nanofabrication of large sinusoidal metrology grids. The diamond turning machine has a T-base design, which consists of a spindle with its rotation axis along the Z-direction and a cross-slide with its movement direction along the X-direction. A fast-tool-servo (FTS) unit is mounted on the X-slide to generate sinusoidal microstructures on a flat workpiece surface mounted on the spindle. The error motions of the X-slide and the spindle, which introduce Z-directional profile errors (out-of-flatness) on the grid surface, are measured and compensated. The out-of-straightness of the X-slide is measured to be approximately 60 nm over a travel of 80 mm by using the reversal method. It is also confirmed that the out-of-straightness of the X-slide has a 10-nm periodic component with a period of 11 mm corresponding to the diameter of the needles used in the roller bearing of the X-slide. The angular motion of the spindle is measured to be approximately 0.3″ by using an autocollimator, which can cause a 73-nm out-of-flatness over a workpiece 100 mm in diameter. The axial motion of the spindle is measured to be approximately 5 nm, which is the smallest error motion. The out-of-flatness of the workpiece is reduced from 0.27 to 0.12 μm through compensating for the error motions by utilizing the FTS unit based on the measurement results of error motions.     

Experiences with the master axis method for measuring spindle error motions

In this paper, the master axis method of machine tool spindle measurement is described. This method allows spindle measurements to be carried out at speed and under load. For example, a radial load representing the cutting force in a turning operation can be conveniently applied during characterization of a lathe spindle. The synchronous and asynchronous error motions have been observed to vary in both magnitude and shape with changes in load. Test results from both static and dynamic loads during testing are shown to demonstrate the utility of the method.     

First and second order periodic error measurement for non-constant velocity motions

This paper describes a digital algorithm that can be applied in real time to measure and compensate first and second order periodic error in heterodyne displacement measuring interferometers. Comparisons are made between the new algorithm and the traditional frequency domain measurement approach, where the error signal is Fourier transformed into the frequency domain to identify periodic error magnitudes. Experimental results are provided for both constant velocity and non-constant velocity conditions.     

会计信息失真的成因及对策

探讨会计信息失真的原因，提出治理会计信息失真问题的对策，使会计信息失真问题得到有效地遏制。     

A technique to measure fuel oil viscosity in a fuel power plant

The viscosity measurement and control of fuel oil in power plants is very important for a proper combustion. However, the conventional viscometers are only reliable for a short period of time. This paper proposes an on-line analytic viscosity evaluation based on energy balance applied to a piece of tube entering the fuel oil main heater and a new control strategy for temperature control. This analytic evaluation utilizes a set of temperature versus viscosity graphs were defined during years of analysis of fuel oil in Mexican power plants. Also the temperature set-point for the fuel oil main heater output is obtained by interpolating in the corresponding graph. Validation tests of the proposed analytic equations were carried out in the Tuxpan power plant in Veracruz, Mexico.     

基于电容传感原理的低成本砂石计量技术

基于电容式料位测量原理,尝试将电容式传感技术应用于混凝土搅拌设备中的砂石计量,为此自制了实验用电容式砂石料位传感器并开发了以AT89C51单片机为核心的低成本电子测量系统．通过对该传感器信号处理关键技术的探讨,开发出了能适应混凝土搅拌设备需要的电容信号长线传输方法和测量电路．实验表明,基于电容传感原理的砂石计量已有较高精度,有可能为混凝土搅拌设备提供一种成本低、适应工地现场复杂工作环境的砂石计量方法,     

Development of a real-time look-ahead interpolation methodology with spline-fitting technique for high-speed machining

Methodologies for converting short line segments into parametric curves were proposed in the past. However, most of the algorithms only consider the position continuity at the junctions of parametric curves. The discontinuity of the slope and curvature at the junctions of the parametric curve might cause feedrate fluctuation and velocity discontinuous. This paper proposes a look-ahead interpolation scheme for short line segments. The proposed interpolation method consists of two modules: spline-fitting and acceleration/deceleration (acc/dec) feedrate-planning modules. The spline-fitting module first looks ahead several short line segments and converts them into parametric curves. The continuities of the slope and curvature at each junctions of the spline curve are ensured. Then the acc/dec feedrate-planning module proposes a new algorithm to determine the feedrate at the junction of the fitting curve and unfitted short segments, and the corner feedrate within the fitting curve. The chord error and acceleration of the trajectory are bounded with the proposed algorithm. Simulations are performed to validate the tracking and contour accuracies of the proposed method. The computational efforts between the proposed algorithm and the non-uniform rational B-spline (NURBS)-fitting technique are compared to demonstrate the efficiency of the proposed method. Finally, experiments on a PC-based control system are conducted to demonstrate that the proposed interpolation method can achieve better accuracy and reduce machining time as compared to the approximation optimal feedrate interpolation algorithm.     

Thermal characteristics analysis and error prediction for lubricated multi-link high-speed precision presses

Thermal models are important in the process of predicting the thermal characteristics and corresponding thermal error of multi-link high-speed precision presses (MLHSPPs) with an oil-lubrication system. Previous models only involved the effects of bearing stiffness, temperature change of bearings, flexibility of crank shaft on the heat generation power, while the influences of revolute clearance joint and flexibility of linkage are seldom considered, which inevitably reduces the accuracy of thermal analysis. To overcome this problem, dynamic models of flexible multi-link mechanisms (MLM) with clearance, lubrication, crankshaft-bearing system are constructed, the interaction forces between pin and bushing are obtained to calculate its heat generation power. Then, an improved model of MLHSPP with lubrication is proposed to analyze the temperature evolution and the thermal error between slider and work table at the position of LDP, by considering bearing stiffness, temperature change of bearings, flexibility of crank shaft, linkage, clearance, lubrication and thermal contact resistance all together. Compared with results from traditional models, the simulation data from this improved thermal model agree well with experiment, which proves the validity of the proposed model. Furthermore, the temperature rise and the thermal error of MLHSPP between slider and work table at the position of LDP under different input speeds, lubricating oil flux and contact angles of ball bearing were also studied.

     

水表安装时的计量误差实验探讨

水表在实际现场安装中如果达不到安装要求,就会引起弯头、T型接头、变径及其所处的位置上、下游扰动,影响非容积式水表的精确度。利用水表检定装置做了模拟现场的相关试验,并得出了结论,及时掌握这些扰动带来的水表计量误差及趋势,以供水表安装人员参考。     

An image processing technique for high-speed measurement of particle-size distributions

This paper describes an image processing technique for the high-speed measurement of particle-size distributions. When an image of many small particles distributed on a plane is given, it is not difficult to determine the size of each particle by measuring the area of the particle region. However, since we have usually a large number of particles on an image, this conventional technique requires considerable processing time. When real-time processing is essential, a new high-speed processing technique must be developed.The technique proposed in this paper is one based on sampling. We use a number of parallel lines to obtain a distribution of ‘run-length’. By employing a TV camera for image pick-up, we can use its scanning lines as the sampling line. When a scanning line moves across a particle region, a run-length is obtained. After the scanning of one image frame, we obtain a distribution of run-lengths for the image frame.Next, the run-length distribution is converted to the particle size distribution. If each particle region is a circle, this conversion can be done by solving a simple linear equation. This calculation can be performed in real-time processing even with a microcomputer.Theoretically, this conversion becomes unstable if we select the size resolution too small. Then some considerations for stable and high-speed calculation have been discussed for practical applications.