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DOI: 10.1243/095440506X77643
Abstract: The objective of this work is to enhance the accuracy of a double-column machining
centre by compensating thermal errors using software. Characteristics of the thermal errors
were analysed by carrying out a sequence of tests. Temperature measurements were carried
out with thermocouples. Capacitance probes were used to measure the thermal errors. A
multiple linear regression-based technique was applied to correlate the thermal errors to the
temperature distribution. The signals of the measured temperatures were sent to a central
processing unit board inside a computer numerical controller. The predicted thermal errors,
based on the regression model, were sent to the controller for real-time error compensation.
Test results show that a 90 per cent reduction in thermal errors has been achieved after
compensation.
JEM388 IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
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110 Cheng-Hsien Wu and Yu-Tai Kung
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM388 IMechE 2006
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Thermal analysis and compensation of a double-column machining centre 111
JEM388 IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
Downloaded from pib.sagepub.com at PENNSYLVANIA STATE UNIV on March 5, 2016
112 Cheng-Hsien Wu and Yu-Tai Kung
Fig. 4 (a) Measured temperature and (b) thermal error versus time with the spindle rotating
does not move along the bridge. One possibility is The temperature variation is measured with the
that the spindle heat is conducted to the ball-screw thermocouples and the data are shown in Fig. 5(a).
feed drive system on the y axis. However, the ball- The heat sources on the ball screw are frictions
screw temperatures on the y axis have been almost caused by the nut and two support bearings of the
constant. There should be little thermal expansion y-axis feeding system. The temperatures at two
of the y-axis ball screw. Another possibility is that bearings reach 7.5 C and 12.3 C respectively. The
the y-axis error results from thermal distortion of temperature rise induces thermal expansion of the
the spindle. The motor is installed at the lower right feeding system. As the left-hand side of the ball
position of the spindle. Generated heat leads to a screw is fixed, the ball screw expands to the right.
non-uniform spindle temperature. The maximum This expansion causes a positive thermal error on
values of T1, T2, and T3 are 8.5 C, 8.8 C, and the y axis. On the other hand, a 17 mm thermal error
12.8 C respectively. A higher temperature on the on the z axis also exists. The z-axis thermal error
lower right distorts the spindle. As a result of arises in two possible ways.
this, the spindle may bend to the left and create a
1. The heat generated by the feeding system on the y
negative y-axis thermal error.
axis is conducted to the spindle and leads to spin-
dle expansion.
3.2 Case 2: with the spindle moving along the 2. The heat source inside the spindle causes the
y axis without rotation temperature rise and thermal expansion.
The spindle head reciprocates at a speed of 10 m/min Detailed analytical procedures are carried out as
for 2 h. The feed rate is increased to 20 m/min for follows. The spindle temperatures T1, T2, and T3
another 2 h and to 30 m/min for the last 2 h. approach 1.9 C, 0.8 C, and 2.1 C respectively.
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM388 IMechE 2006
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Thermal analysis and compensation of a double-column machining centre 113
Fig. 5 (a) Measured temperature and (b) thermal error versus time with the spindle moving along the y axis
The top of the spindle has a lower temperature than The temperature rise may have produced a 17 mm
the bottom of the spindle. Therefore, there must be a thermal expansion on the z axis. To verify the ther-
heat source inside the spindle. The ball-screw mal characteristics of the cooling system, a further
temperatures T5, T6, T7, and T8 are almost at the analysis follows in the next case.
same level as room temperature. Therefore, it is not
possible that the heat comes from the friction of
3.3 Case 3: with the machining centre turned on
the y-axis feeding system. However, the spindle
does not rotate in this case. To find the heat source, The machining centre is turned on and no further
a detailed study is conducted as follows. rotation or movement is executed. The coolant
There is a cooling system inside the machining temperature increases to as high as 5.8 C. The only
centre. When the power of the machining centre is heat source is the pump of the coolant system.
switched on, the coolant of the cooling system circu- When the machining centre is turned on, the coolant
lates in the spindle. The cooling system serves two circulates around the spindle and the spindle tem-
functions. One is as a pump to force the coolant to perature rises. The spindle temperatures T1, T2, and
flow. The pump works whenever the machining T3 are measured and the maximum values are
centre is in the ‘on’ condition. The other is as a 1.9 C, 0.8 C, and 2.1 C respectively. The z-axis
refrigerator. It works only when the coolant tem- thermal error reaches as high as 41 mm. This means
perature exceeds the upper limit. In this case, the that the thermal error is 7.1 mm when there is a 1 C
coolant temperature remains at the upper limit, rise in coolant temperature. The coolant tempera-
41 C. The refrigerator never works during the 6 h ture increases to 2.2 C in the previous case. To
period. The pump generates heat and causes simplify the analysis, the thermal expansion of the
a 2.2 C increase in the coolant temperature. spindle is assumed to be linear with the coolant
JEM388 IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
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114 Cheng-Hsien Wu and Yu-Tai Kung
Fig. 6 (a) Measured temperature and (b) thermal error versus time with the spindle reciprocating
temperature rise. Then an increase of 2.2 C in the 1000 r/min and 6 m/min respectively. The speed
temperature of the coolant is assumed to create a and feed rate are 2000 r/min and 8 m/min respec-
15.6 mm thermal error on the z axis (2.2 C · tively for the second 2 h, and 3000 r/min and
7.1 mm/ C). The result is close to the measured ther- 10 m/min respectively for the last 2 h. The tempera-
mal error on the z axis (17 mm). With these results, ture variation and thermal error are shown in Fig. 7.
the pump is believed to be the only source of the The temperatures of both spindle and feeding sys-
z-axis thermal error. The heat transfer from the feed- tem increase during this period. The spindle and the
ing system of the y axis to the spindle can therefore coolant are subjected to an abrupt temperature
be neglected. change at 300 min. Obviously, the refrigerator starts
to operate because the coolant temperature exceeds
3.4 Case 4: with the spindle rotating and the
the upper limit, 41 C. The thermal errors reach
y-axis feeding system running simultaneously
120 mm on the z axis and 6.5 mm on the y axis.
In this case, the spindle rotates and the y-axis Case 4 can be regarded as a combination of cases
feeding system runs simultaneously. One purpose 1 and 2. The spindle rotates at 1000, 2000, and
is to check whether these two thermal errors can 3000 r/min in case 1. The z-axis thermal error is
be superposed to obtain the total thermal error. 114 mm and the y axis thermal error is 28 mm. The
The other purpose is to develop a mathematical feed rates are 6, 8, and 10 m/min in case 2. The
model for the thermal error by implementing the thermal errors are 17 mm on the z axis and 25 mm
experimental data. The whole period lasts for 6 h on the y axis. The superposition of these two cases
and is equally divided into three stages. The rota- gives thermal errors of 131 mm on the z axis and
tional speed and y-axis feed rate for the first 2 h are 3 mm on the y axis. The measured thermal errors
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM388 IMechE 2006
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Thermal analysis and compensation of a double-column machining centre 115
Fig. 7 (a) Measured temperature and (b) thermal error versus time with the spindle rotating and the y-axis feeding system
running simultaneously
of case 4 are 120 mm and 5 mm on the z axis and equation that expresses the response as a linear
y axis respectively. They are in good agreement, function of the p predictors is estimated using the
which means that the thermal errors of spindle and measured data. The model is specified by a linear
feeding system can be superimposed on each other equation
in this study.
Y ¼ b0 þ b1 X1 þ þ bp Xp þ e ð1Þ
4 ERROR COMPENSATION MODEL Matrix notation will simplify most of the results
used in the multiple-linear-regression analysis. Let
Thermal errors are time variant during machining. Y and e be n · 1 vectors whose elements are given
The machining centre can be compensated on the by the yi and the ei according to
basis of a pre-established empirical model which 2 3 2 3
correlates the thermal errors to the measured tem- y1 e1
6 y2 7 6 e2 7
perature. Various methods have been implemented 6 7 6 7
Y ¼ 6 . 7, e ¼ 6 .. 7 ð2Þ
to model the thermal errors of machine tools. 4 .. 5 4 . 5
A multiple-linear-regression analysis is applied to yn en
develop a thermal error model in this study.
In the multiple-regression analysis, several predic- Also, define b to be the vector parameter of length
tors are used to model a single response variable. For (p þ 1) · 1, including the intercept b0, according to
each of the n cases observed, values for the response 2
3
b1
and for each of the predictors are collected. If the 6 b2 7
response is called Y, and the predictors are called 6 7
b¼6 . 7 ð3Þ
X1, X2,. . ., Xp, then the data will form an n · (p þ 1) 4 .. 5
array. In the multiple-linear-regression analysis, an bn
JEM388 IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
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116 Cheng-Hsien Wu and Yu-Tai Kung
Next, define X to be an n · (p þ 1) matrix given by Ten running tests have been carried out and the
2 3 measured data collected. The tests include opera-
1 x11 x12 : x1p tions with various spindle speeds and feed rates.
6 1 x21 x22 : x2p 7
6 7 If three predictors are included in the multiple-
X ¼6
6: : : : : 77 ð4Þ
4: : : : : 5 linear-regression model, three temperatures T1, T2,
1 xn1 xn2 : xnp and T3 are found the best choice. The mathematical
equation can be expressed as
Using these quantities, the multiple-linear-
Ez ¼ 5:505 þ 3:388T1 þ 2:238T2 þ 3:97T3 ð7Þ
regression equation can be written in matrix terms
as The coefficient of determination is found to be
Y ¼ Xb þ e ð5Þ 0.997, which means the ability of prediction is
The regression model using the least-squares 99.7 per cent. Using this model gives a high
method is determined by minimizing the residual accuracy; however, it needs three thermal sensors
sum of squares. The coefficient of determination is to compensate errors on line. If fewer sensors are
defined as preferred, simpler models can be derived. If two
thermal sensors are installed in error compensation,
SYY RSS T2 and T3 are the key temperatures to be measured.
R2 ¼ ð6Þ
SYY The coefficient of determination is found to be
0.996. If only one thermal sensor is set up in error
where SYY is the corrected sum of squares for the
compensation, measuring T2 is found to be the best
yi and RSS is the residual sum of squares. The
choice. The coefficient of determination is found to
coefficient gives the portion of variability in Y
be 0.994. If the number of sensors is larger, the
explained by regression on the X.
prediction ability becomes greater.
In this study, the thermal error modelling is based
on a multiple-linear-regression analysis. The res-
ponse is the thermal error Ez on the z axis, and the 5 REAL-TIME COMPENSATION SCHEME
predictors are the measured temperatures T1, T2,. . ., AND RESULTS
Tk. The procedures can be summarized as follows.
1. Determine the response (z-axis thermal error) In this study, the model in equation (7) is implemen-
and find the adequate predictors; then run the ted for compensating the thermal error on the z axis.
experiments and collect the data. The method used in this study is to shift the origins
2. Derive the multiple-regression equations and cal- of the axes. The compensation method utilizes a
culate the least-squares estimators. central processing unit board inside the computer
3. Validate the estimators. numerical controller. During operation processes,
4. Specify the probability distribution of the random the temperature signal is collected in real time and
error component e and estimate the variance. the errors are estimated with the regression model.
5. Check the estimators and verify the accuracy of Finally, the compensation signals are sent to the
the model. computer numerical controller to shift the origins
6. Apply the multiple-linear-regression model for of the slide axes to adjust the relative position
thermal error compensation. between the spindle tip and the working table.
Fig. 8 Measured thermal errors versus time with and without real-time compensation
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Thermal analysis and compensation of a double-column machining centre 117
Resultant z-axis thermal errors before and after in real time. Tests results show that the z-axis
compensation are shown in Fig. 8. The thermal thermal error of the machining centre has been
errors of the double-column machining centre are reduced from 120 to 12 mm.
reduced from 120 to 12 mm.
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JEM388 IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
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