CIRP Journal of Manufacturing Science and Technology 25 (2019) 22–25

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CIRP Journal of Manufacturing Science and Technology

journal homepage: www.elsevier.com/locate/cirpj

Adaptive thermal displacement compensation method based on deep

learning
Makoto Fujishima(3)a , Koichiro Narimatsua,* , Naruhiro Irinoa , Masahiko Mori(1)a ,
Soichi Ibaraki(2)b
a
DMG MORI Co., Ltd., Meieki 2-35-16, Nakamura, Nagoya 450-0002, Japan
b
Department of Mechanical Systems Engineering, Hiroshima University, Kagamiyama 1-4-1, Higashi-Hiroshima 739-8527, Japan

A R T I C L E I N F O A B S T R A C T

Article history: Temperature variation of the machine tool structure due to machine internal heat generation or heat
Available online 16 May 2019 exchange with the ambient environment causes thermal deformation. To compensate the deformed
machines, various methods have been proposed. However, these methods failed to compensate machines
in severe situations such as unexpected temperature change and sensor failure. In this paper, a novel
Keywords: thermal displacement compensation method using deep learning is proposed. In the proposed algorithm,
Machine tool
reliability in thermal displacement prediction is evaluated based on deep learning to change the
Thermal error
compensation weight adaptively. High-performance thermal displacement compensation result on
Compensation
turning center is presented.
© 2019 CIRP.

Introduction displacement prediction from the temperature under the ambient

In recent years, due to lack of labor force in the manufacturing
industry, automation systems and robotized workpiece transpor-
tation systems have been required for unmanned or reduced
personnel factory. For continuous machining operation by
automation, it is important to suppress the deterioration of
accuracy. Thermal deformation has significant effects on the
machining accuracy under machining operation. Internal and
external heat sources of machine tools and their changes are the
main factor that deteriorates the machining accuracy. To achieve
high quality and high-performance automated manufacturing
system, the techniques to successfully suppress thermal displace-
ment have been required. Much research has been carried out on
this topic. However, not many good results were gained in practice.
Against this issue, various thermal displacement control techni-
ques by controlling temperature and compensation techniques have
been developed [1,2]. For example, method using thermal sensors
[3–6], prediction from NC unit internal data [7] and prediction by
neural networks [8] were developed. In recent years, in the artificial
intelligence technologies including deep learning, the performance
of image recognition has become more accurate [9–11].
The authors presented that convolutional neural network
model using deep learning had high performance of thermal
* Corresponding author.
E-mail address: ko-narimatsu@dmgmori.co.jp (K. Narimatsu).
temperature change [12]. On the other hand, in order to apply deep
learning technology to the industrial field and to compensate
thermal displacement, it is important to clarify the reliability of
prediction. In case of low prediction reliability, such as the
unlearned operating condition and sensor failure, it is necessary to
suppress the deterioration of accuracy.
In this paper, the reliability evaluation method based on
Bayesian dropout [13] is presented. Adaptive compensation
method which adjusts the compensation value based on the
evaluated reliability value is proposed. This method can prevent
the deterioration of accuracy due to extreme compensation values
caused by sensor failure with extreme fluctuation of measured
value due to disconnection. This method also adapts to cutting heat
generation, operating heat generation, such as spindle rotation and
axes movement, and ambient temperature change. The results
show that the deterioration of accuracy can be adaptively
prevented according to the mode of sensor failure.
Calculating prediction uncertainty in deep learning
A deep learning regression predicts some value from input data.
In the prediction of thermal displacement, displacement value is
predicted from data such as values of temperature sensors. In the
deep learning classification and the distinction, reliability of
prediction is evaluated by using ‘softmax’ as an output function
[13]. However, it has been difficult to easily calculate reliability in
the deep learning regression.

https://doi.org/10.1016/j.cirpj.2019.04.002
1755-5817/© 2019 CIRP.
 M. Fujishima et al. / CIRP Journal of Manufacturing Science and Technology 25 (2019) 22–25
Fig. 1. Schematic diagram of dropout.
The ‘Bayesian dropout’ approach uses dropout to evaluate
reliability by calculating uncertainty. Dropout technique has been
widely used to prevent overfitting of deep learning models [14,15].
The concept of dropout for neural networks used in deep learning is
shown in Fig. 1. The dropout technique is normally used to train
models, but Bayesian dropout uses dropout technique not only
during training, but also during prediction. This method can be easily
implemented because trained model can be used without modifica-
tion and no additional processing is required for input data.
The results of the displacement prediction from temperature
using Bayesian dropout are shown in Fig. 2. The blue line is the
measured thermal displacement of a turning center in X-axis
direction, which is the direction of change in diameter, in the spindle
operating condition. In order to calculate the prediction uncertainty
range, dropout was applied to the trained deep learning model for
displacement prediction, and the calculations were repeated 100
times while switching the node to be dropped. From the calculated
values, the distribution of the predicted values shown in green color
density. The thin red lines are the prediction uncertainty range
(mean  2s ). The tick red line is the predicted displacement.
Thermal displacement prediction from temperature under
various operating conditions
Thermal displacement under various operating conditions
Thermal displacement and temperature data of the turning center
were collected to investigate the accuracy and uncertainty of thermal
displacement prediction under various operating conditions. The
Fig. 2. Calculation results of prediction uncertainty.
23
Fig. 3. Machine structure of turning center.
Fig. 4. Displacement sensors and directions.
temperature values are measured by thermocouples attached on the
machine structure of the turning center shown in Fig. 3, and the
displacement values are obtained by measuring the relative movement
between workpiece and turret. As shown in Fig. 4, there are five
displacement sensors: two are for measuring displacement in machine
X-axis direction, two are for Y-axis direction, and one is for Z-axis
direction.
Table 1 shows the variants in the experimental conditions. On
and off of coolant heating to emulate the cutting heat, spindle
operation, axes movement, and ambient temperature change are the
variants. Thermal displacement was measured with single operating
condition turned on by itself and combination of two operating
conditions. The movable temperature variable booth shown in Fig. 5
was used for the ambient temperature change condition.
Thermal displacement prediction by deep learning and evaluation of
prediction uncertainty
Using the collected data, thermal displacement prediction and
calculation of prediction uncertainty were carried out by deep
learning. The neural network model shown in Fig. 6 was used for
training and prediction. Temperature values for 30 min of 12
temperature sensors were given as input data. 5 displacement
values were also given as supervised data. From the collected data,
41 data from 3 machines were used as training data, 8 data from
other 3 machines were used as evaluation data.
The results of the prediction and the prediction uncertainty are
shown in Fig. 7. The blue line is the measured thermal
displacement of the X-axis direction. The tick red line is the
Table 1
Experimental variants.
Name Operating condition
Condition 1 Coolant heated at the equivalent heat of cutting
Condition 2 Spindle running for 8 h at 4,000 min 1
Condition 3 X and Z axes moving at 30,000 mm/min for 8 h
Condition 4 Ambient temperature increasing and decreasing by 8  C in 9 h
24 M. Fujishima et al. / CIRP Journal of Manufacturing Science and Technology 25 (2019) 22–25

Fig. 5. Movable temperature variable booth and air conditioner.

Fig. 7. Prediction results of displacement in the X-axis.

Table 2
Sensor failure simulation modes.

Failure mode Value

Mode 1. Resistive sensor contact failure NV/OR switch randomly
Mode 2. Voltage sensor disconnection 0
Mode 3. Resistive sensor disconnection OR
Mode 4. Voltage sensor contact failure NV/0 switch randomly

NV: normal value, OR: over range ( 128  C).

of disconnection. Voltage sensors (modes 2 and 4) output zero value

Fig. 6. Schematic diagram of neural network model.
predicted displacement. The thin red lines are the prediction
uncertainty. The (a1) and (a2) charts are evaluation data, the (b1)
and (b2) charts are training data, the (a1) and (b1) charts are
ambient temperature change conditions, and the (a2) and (b2)
charts are main spindle operating conditions. Despite the training
data and the evaluation data are measured in the same condition
but on different machines, the prediction accuracy and the
uncertainty are similar degrees. Therefore, it can be appeared
that the trained model has robustness for the unlearned data.
in case of disconnection. Assuming that one of the input temperature
sensors failed, displacement was predicted by inputting the wave-
forms shown in Fig. 8 to the trained model.
Fig. 9 shows the prediction results of X-axis thermal displace-
ment and the prediction uncertainty. In the failure modes 1 and 3,
the values of the predicted thermal displacement greatly change at
around 10 h when sensor signal fails and the prediction
uncertainty also increase simultaneously. On the other hand, in
the failure modes 2 and 4, the influences on the prediction
accuracy are small, and a change in uncertainty is hardly observed.
As described above, in a situation where the prediction accuracy
deteriorates due to a failure of the sensor, it can be determined that

Prediction uncertainty variation and adaptive adjusting in

thermal displacement compensation value

Prediction uncertainty variation due to sensor failure simulation

In order to investigate how much the displacement prediction

accuracy and the prediction uncertainty change when an unintended
fluctuation occurs in the input temperature data, thermal displace-
ment was predicted with intentionally tampering temperature
sensor data to emulate sensor failure. Table 2 shows the sensor
failure modes. Two types of temperature sensors were considered to
simulate values when the sensor is disconnected. Resistive sensors
(modes 1 and 3) output an extreme abnormal value ( 128  C) in case Fig. 8. Simulated waveforms of sensor failure.
 M. Fujishima et al. / CIRP Journal of Manufacturing Science and Technology 25 (2019) 22–25
Fig. 9. Simulation results of sensor failure.
Fig. 10. Simulation result of compensation value adjust at sensor failure.
the prediction reliability has deteriorated from the increased
uncertainty. If a threshold value is set for the uncertainty, it is
possible to detect that prediction accuracy deteriorates.
Adaptive adjusting of compensation value based on prediction
uncertainty
If the prediction uncertainty is large, prediction reliability is
deteriorated. To suppress the deterioration of the compensation
accuracy, the compensation values were overridden using a
function of uncertainty value. The moving average filter param-
eters were also adjusted to obtain a smooth fluctuation of
compensation value. Fig. 10 shows the simulation results with
adjusted compensation values based on the prediction uncertainty.
The blue line is the measured thermal displacement of the X-axis
direction. The red line is the predicted displacement. The light blue
line is the adjusted compensation values. The uncertainty values
greatly affected by the sensor failure simulation in failure modes 1
and 3. The deterioration of accuracy can be suppressed by adjusting
the compensation values. On the other hand, in the failure modes 2
and 4, which have small influence on the uncertainty due to the
sensor failure, the compensation values are not adjusted, and good
accuracy is maintained.
25
By adjusting the compensation value based on the uncertainty, the
deterioration of accuracy can be adaptively prevented when a failure of
the sensor or an unexpected machine operating condition occurs.
Conclusion
In this paper, the prediction reliability evaluation method for
thermal displacement prediction based on Bayesian dropout was
presented. The method adapted to not only ambient temperature
change but also cutting heat generation and operating heat
generation by spindle rotation or axes movement. The results
showed that the trained deep learning model had good prediction
performance and the method could evaluate prediction reliability
as uncertainty. By adjusting the compensation values based on the
uncertainty, the method can prevent the deterioration of accuracy
due to extreme prediction values caused by sensor failure.
Conflict of interest
Makoto Fujishima and Masahiko Mori are board menbers of
DMG MORI CO., LTD. Koichiro Narimatsu and Naruhiro Irino are
employees of DMG MORI CO., LTD. Soichi Ibaraki is an academic
supervisor of Koichiro Narimatsu.
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