Precision digital twin of production machines for sustained high accuracy and traceable part conformity

在许多制造过程中，机器相对于工件移动刀具。根据工艺，例如减法或加法，工具可以是例如切割工具、激光束或沉积喷嘴。加工零件的几何和尺寸质量在很大程度上取决于这些机器的定位和轨迹跟踪的精度。定制化产品和小批量生产增加了对高精度机器的需求。精度受机床内部几何形状的影响，该几何形状与标称的几何形状不同，在运动轴之间的对准和每个轴的运动中都表现出缺陷。进一步的几何变化是由磨损、热效应、顺应性或缺乏刚性以及滞后引起的。需要大量的资源来制造好的零件，并通过计量学来验证它们的一致性。在过去的几十年里，人们致力于研究在无载荷条件下发生的准静态几何误差。这一建议针对的是表现出非线性行为和/或违反刚体假设的现象，因此不会假定该假设适用。该研究计划旨在开发模型、技术和方法，以提供机床的实时数字孪生兄弟，通过不断向机床控制器提供直接轴命令校正或现场计算机数字控制器(CNC)校正模型的更新参数来获得稳健和持续的机床精度。同时，通过未来的研究，这种模型可以发布生产部件的可追溯性符合性状态，从而减少生产后检查的需要。除了丰富的模型外，还将研究精益、健壮、快速和自动化的车间兼容方法，以使模型与其实际物理对应物相匹配。这对数字孪生兄弟将同时使用基于物理的洞察模型和误差表示模型。使用激光干涉仪和测功机等实验室设备进行的详细实验将为模型开发提供必要的知识。然后，将研究和测试使用在线传感器(如接触式和非接触式探头和惯性测量单元)以及无传感器方法现场校准模型的方法。现代机器的CNCS提供的信号将被充分利用以达到这一目的。该程序将促进对机床非线性和非刚性误差源的理解。除了科学文化，该计划还将为HQP提供制造计量、机器误差及其补偿方面的专业知识。加拿大工业将通过技术转让和训练有素的总部基地人员，在国际竞争对手之前及早获得新知识和技术。

In many manufacturing processes a machine moves a tool relative to a workpiece. Depending on the process, such as subtractive or additive, the tool can be, for example, a cutting tool, laser beam or deposition nozzle. The geometric and dimensional quality of manufactured parts depends largely on the accuracy of positioning and path following of these machines. Customised products and small batch production increase the demands for highly accurate machines. Accuracy is affected by the built geometry of the machine, which differs from nominal, exhibiting imperfections in the alignment between moving axes and in the motion of each axis. Further geometry changes are caused by wear and tear, thermal effects, compliance or lack of stiffness, and hysteresis. Much resources are needed to make good parts and also to verify their conformity by metrology. Over past decades, much effort has been dedicated to quasi-static geometric errors occurring under no load conditions. This proposal is directed at phenomenon that exhibit non-linear behaviour and/or defy the rigid body hypothesis, which as a result will not be assumed to apply. The research program aims at developing the models, technologies and methodologies to provide a continuously updated live digital twin of the machine to obtain robust and sustained machine accuracy by continuously feeding the machine controller with either direct axis command corrections or updated parameters for in-situ computer numerical controller (CNC) correction models. In parallel, such models could, through future research, issue a traceable conformity status of the produced part thus reducing the need for post-production inspection. In addition to rich models, lean, robust, fast and automated shop-floor compatible means will be researched to match the model to its actual physical counterpart. The digital twin will use both physics-based models, for insight, and error representation models. Detailed experiments using laboratory equipment such as laser interferometers and dynamometers will provide the essential knowledge for model development. Then, means to calibrate the models in-situ using online sensors such as contact and non-contact probes and inertial measuring units, but also sensorless approaches, will be researched and tested. Signals made available by modern machines' CNCs will be exploited fully for this purpose. The program will advance the understanding of machine tools non-linear and non-rigid error sources. In addition to a scientific culture, the program will provide HQPs with expertise in manufacturing metrology, machine errors and their compensation. Canadian industry will have early access to the new knowledge and technologies before their international competitors through technology transfer and through the trained HQPs.