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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
Automation and Drives
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
Automation and Drives
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
Automation and Drives
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 !!
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
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
Industry SectorVolumetric Compensation System
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
Industry SectorVolumetric Compensation System
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
Industry SectorVolumetric Compensation System
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
Industry SectorVolumetric Compensation System
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
Industry SectorVolumetric Compensation System
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
Confidential
Industry SectorVolumetric Compensation System
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
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 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 info@afm-tec.de
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: info@afm-tec.de
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: w.meyer@afm-tec.de
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 16/18 14.03.2008Seite 16Wolfram Meyer LacerTracer-Measurement on machine tool
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)
© Siemens AG 2008 - Änderungen vorbehalten
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
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 18/18 14.03.2008Seite 18Wolfram Meyer LacerTracer-Measurement on machine tool
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)
© Siemens AG 2008 - Änderungen vorbehalten
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
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 20/18 14.03.2008Seite 20Wolfram Meyer
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
LacerTracer-Measurement on machine tool
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 21/18 14.03.2008Seite 21Wolfram Meyer
Positioning error of the X-Axis
LacerTracer-Measurement on machine tool
XTX
© Siemens AG 2008 - Änderungen vorbehalten
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
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 23/18 14.03.2008
Positioning error of the Z-Axis
Seite 23Wolfram Meyer LacerTracer-Measurement on machine tool
-1500.0
ZTZ
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 24/18 14.03.2008
Straightness error of the X-Axis
Seite 24Wolfram Meyer LacerTracer-Measurement on machine tool
XTY
XTZ
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 25/18 14.03.2008
Straightness error of the Y-Axis
Seite 25Wolfram Meyer LacerTracer-Measurement on machine tool
YTX
YTZ
-1500.0
-1500.0
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 26/18 14.03.2008
Straightness error of the Z-Axis
Seite 26Wolfram Meyer LacerTracer-Measurement on machine tool
ZTX
ZTY
-1500.0
-1500.0
© Siemens AG 2008 - Änderungen vorbehalten
A&D MC MT P3Seite 27/18 14.03.2008
Yaw-, Pitch- and Roll- Error
Seite 27Wolfram Meyer LacerTracer-Measurement on machine tool
-1500.0
-1500.0-1500.0 -1500.0
-1500.0
-1500.0
XRX XRY XRZ
YRX YRY YRZ
ZRX ZRY ZRZ
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 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
Siemens VCS Verification / Feb. 2008
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
Siemens VCS Verification / Feb. 2008
Linear Positioning of the X-Axis
X
X
X
Position 1
Position 2
Position 3
Siemens VCS Verification / Feb. 2008
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
Siemens VCS Verification / Feb. 2008
Straightness Measurement of the X-Axis
VCS on
-74%
VCS off
VCS on
-62%
VCS offXTY
XTZ
Siemens VCS Verification / Feb. 2008
Linear Positioning of the Y-Axis
Position 1
Position 2
Y
Y
Siemens VCS Verification / Feb. 2008
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
Siemens VCS Verification / Feb. 2008
Straightness Measurement of the Y-Axis
VCS on
-62%
VCS off
VCS on
-38%
VCS off
YTX
YTZ
Siemens VCS Verification / Feb. 2008
Circularity Tests
Position 1:
x-y-Plane
Position 2:
y-z-Plane
Siemens VCS Verification / Feb. 2008
Circularity Tests
Position 1: x-y-Plane
Improvement of Circularity: -36%
Improvement of Squareness: -94%
VCS off VCS on
Siemens VCS Verification / Feb. 2008
Circularity Tests
Position 2: y-z-Plane
Improvement of Circularity: -48%
Improvement of Squareness: -58%
VCS off VCS on
Siemens VCS Verification / Feb. 2008
VCS Orientation Compensation
Wyler
Blue LevelPosition 1:
C=0 A=90
Position 2:
C=90 A=90
Siemens VCS Verification / Feb. 2008
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%
Siemens VCS Verification / Feb. 2008
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%
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 VCS Verification / Feb. 2008
VCS Summary
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