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Title: Software based controls module development

Abstract

A project was initiated at the Oak Ridge Y-12 Plant to implement software geometric error compensation within a PC-based machine tool controller from Manufacturing Data Systems, Inc. This project may be the first in which this type of compensation system was implemented in a commercially available machine tool controller totally in software. Previous implementations typically required using an external computer and hardware to interface through the position feedback loop of the controller because direct access to the controller software was not available. The test-bed machine for this project was a 2-axis Excello 921 T-base lathe. A mathematical error model of the lathe was created using homogeneous transformation matrices to relate the positions of the machine's slides to each other and to a world reference system. Equations describing the effects of the geometric errors were derived from the model. A software architecture was developed to support geometric error compensation for machine tools with up to 3 linear axes. Rotary axes were not supported in this implementation, but the developed architecture would not preclude their support in the future. Specific implementations will be dependent upon the configuration of the machine tool. A laser measuring system from Automated Precision, Inc. was used tomore » characterize the lathe's geometric errors as functions of axis position and direction of motion. Multiple data files generated by the laser system were combined into a single Error File that was read at system startup and used by the compensation system to provide real-time position adjustments to the axis servos. A Renishaw Ballbar was used to evaluate the compensation system. Static positioning tests were conducted in an attempt to observe improved positioning accuracy with the compensation system enabled. These tests gave inconsistent results due to the lathe's inability to position the tool repeatably. The development of the architecture and compensation template will provide a baseline platform for investigating other types of error compensation in the future.« less

Authors:
; ;
Publication Date:
Research Org.:
Oak Ridge Y-12 Plant (Y-12), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Defense Programs (DP) (US)
OSTI Identifier:
751192
Report Number(s):
Y/AMT-628; Crada-Y1297-0496
Crada Y1297-0496; TRN: AH200019%%35
DOE Contract Number:  
AC05-84OR21400
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 10 Dec 1999
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 99 GENERAL AND MISCELLANEOUS//MATHEMATICS, COMPUTING, AND INFORMATION SCIENCE; COMPUTERIZED CONTROL SYSTEMS; COMPUTER CODES; LATHES; ERRORS; MATHEMATICAL MODELS; POSITIONING; CUTTING TOOLS

Citation Formats

Graves, v b, kelley, g, and welch, j c. Software based controls module development. United States: N. p., 1999. Web. doi:10.2172/751192.
Graves, v b, kelley, g, & welch, j c. Software based controls module development. United States. https://doi.org/10.2172/751192
Graves, v b, kelley, g, and welch, j c. 1999. "Software based controls module development". United States. https://doi.org/10.2172/751192. https://www.osti.gov/servlets/purl/751192.
@article{osti_751192,
title = {Software based controls module development},
author = {Graves, v b and kelley, g and welch, j c},
abstractNote = {A project was initiated at the Oak Ridge Y-12 Plant to implement software geometric error compensation within a PC-based machine tool controller from Manufacturing Data Systems, Inc. This project may be the first in which this type of compensation system was implemented in a commercially available machine tool controller totally in software. Previous implementations typically required using an external computer and hardware to interface through the position feedback loop of the controller because direct access to the controller software was not available. The test-bed machine for this project was a 2-axis Excello 921 T-base lathe. A mathematical error model of the lathe was created using homogeneous transformation matrices to relate the positions of the machine's slides to each other and to a world reference system. Equations describing the effects of the geometric errors were derived from the model. A software architecture was developed to support geometric error compensation for machine tools with up to 3 linear axes. Rotary axes were not supported in this implementation, but the developed architecture would not preclude their support in the future. Specific implementations will be dependent upon the configuration of the machine tool. A laser measuring system from Automated Precision, Inc. was used to characterize the lathe's geometric errors as functions of axis position and direction of motion. Multiple data files generated by the laser system were combined into a single Error File that was read at system startup and used by the compensation system to provide real-time position adjustments to the axis servos. A Renishaw Ballbar was used to evaluate the compensation system. Static positioning tests were conducted in an attempt to observe improved positioning accuracy with the compensation system enabled. These tests gave inconsistent results due to the lathe's inability to position the tool repeatably. The development of the architecture and compensation template will provide a baseline platform for investigating other types of error compensation in the future.},
doi = {10.2172/751192},
url = {https://www.osti.gov/biblio/751192}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Dec 10 00:00:00 EST 1999},
month = {Fri Dec 10 00:00:00 EST 1999}
}