Sequential Measurement of Position-independent Geometric Errors in the Rotary and Spindle Axes of a Hybrid Parallel Kinematic Machine

We propose a technique to measure position-independent geometric errors (PIGEs) in the rotary and spindle axes of a hybrid parallel kinematic machine (PKM). The PKM investigated here includes one more rotary axis than an Exechon PKM, which is used to improve the productivity of hybrid processes, such as machining and direct-energy-deposition three-dimensional metal printing. Errors in the measured position and orientation of the rotary axis, and the orientation of the spindle axis produce volumetric errors in the processed workpiece. If accuracy is to be improved, the deviation of each axis must be measured and compensated. In our approach, errors are measured using three methodologies that require only control of the rotary axis: in the first, no offset is applied to account for positional deviation of the rotary axis; in the second, an offset is used to correct the orientation of the rotary axis; and in the third, a tool offset is used to correct the orientation of the spindle axis. We developed an algorithm that uses the three measured datasets to identify PIGEs. The proposed method was applied to a hybrid PKM and the PIGEs were measured and compensated. This technique uses simple measurement paths and sequential measurements to correct rotary and spindle axis errors, and could therefore be widely used in industry.