Méthode d'étalonnage d'une machine-outil à cinématique parallèle à cinq axes à grands angles d'inclinaison

A machine-tool is able to manufacture precisely only when it is calibrated. Calibration consists in correcting the model of the machine so that it represents the real kinematics. On no account calibrating a structure consists in changing some parts of the machine. The industrial machining prototype of the Hita-STT (Stiffness Tracking Technology) machine-tool has a four-axis parallel kinematics associated to a turning table as left hand. The spindle is fixed to the parallel kinematics; the workpiece is fixed to the turning table. This new machine-tool was developed by the Laboratoire de Systèmes Robotiques from EPFL and Willemin-Macodel S.A. For its industrialization, it needs an absolute accuracy of 10 microns after calibration considering a repeatability of 5 microns. These specifications should be obtained in the entire workspace between the spindle and the turning device. This doctoral thesis deals with the calibration of the Hita-STT machine-tool. Several methods can be developed. They differ in: the geometrical model that is used. For each kinematics, three geometrical models exist: the implicit model, the forward geometrical model and the inverse geometrical model; the way the corrections are applied. Pose errors are compensated correcting the commands sent to the controller; or the parameters of the structure are identified and updated on the controller. This last solution allows to use a model for the control of the machine that is closer to the real kinematics. These different methods are presented and compared. An optimal calibration method is proposed. Whatever calibration methodology is chosen, it is divided into four steps: modeling the kinematics. An unique distribution of the parameters of the Hita-STT parallel kinematics is proposed; measurement of the pose errors. The choice and the design of the measuring device are presented. A set-up and characterization procedure is explained. It is compatible with the industrial environment. The pose errors measurements are automatic thanks to special ISO functions added to the controller. Data processing is automatic; calculation of the corrections of the model. Several methods are compared in terms of accuracy that can be obtained. An "ideal" method is proposed for the parallel kinematics calibration. It combines the two families of calibration methods, it means an identification method followed by a direct calibration method; implementation. The "ideal" method is tested on the industrial machining prototype Hita-STT. The structure of the programs used to automate the calibration process are given. Tests used to verify the calibration quality are presented. They can also be used to make sure that the parallel kinematics is accurate enough to satisfy the required quality of the manufactured parts.

Design of hybrid-kinematic mechanisms for machine tools

Patric Pham

The machine tool industry is a well established, old and extremely important branch of today's manufacturing industry. With the ongoing globalization and the resulting increase of competition in this industry, the manufacturers have to push their technology to the limits in order to stay competitive. The architecture (kinematics) of most machine tools is based on a serial arrangement of joints and segments, like a human arm. The requirements regarding dynamics, stiffness and precision of these machines brought the scientists and industries to evaluate parallel kinematics for this type of application. Parallel kinematics possess a much higher potential to fulfill these demands, and they would therefore allow the access to a next level of machine performance. Whereas the success of parallel kinematics in domains like packaging is incontestable, it proved to be less evident in machine tools. The low rotation amplitudes and the complexity of the mechanism, the main weak points of parallel kinematics, slow down the development and integration of this kind of machines. In the last few years however, we could observe an increase in development, and more important, in the sales (1)(37)(54) of hybrid kinematic machines. Hybrid kinematics can, by appropriate combination of parallel and serial axes, present a well performing compromise, especially in the machine tool domain where 5 axes/mobilities and high rotation amplitudes are common. The present document is concerned with the mechanical, industrialized design of hybrid-kinematic machine tools and their mechanical elements, and will show that "Hybrid-kinematic mechanisms can outperform fully-parallel mechanisms considering all attributes for a successful and industrialized machine design." The work will point out the limits of fully-parallel mechanisms and justify the use of hybrid solutions. The most important elements of the mechanisms, thereof particularly the spherical and universal joints, will be treated in a detailed manner. Industrialization aspects will be analyzed, the difficulty for their integration will be shown, and solutions provided in order to increase the accessibility of hybrid and parallel mechanisms. A design methodology will be synthesized from all these elements and applied to three case studies. The methodology will point out important and often neglected steps and provide elements and tools to support the designer in the whole process of creation. Furthermore, by providing a broad catalogue of both new and existing hybrid and parallel kinematics, this work is intended to stimulate and inspire the creativity of the designer. The three final cases studies, each differing in their application domain and representing each an unpublished concept, will illustrate and validate the methodology. The work took place around multiple industrial projects and therefore always keeps in mind the practical feasibility, with respect to an industrial environment, and the economic aspects and risks.

EPFL2009

Méthode systématique de conception de cinématiques parallèles

Parallel kinematics structures currently find increasing industrial applications, particularly in packaging and assembly. With very few exceptions, machine-tools with parallel kinematics are limited to mechanisms with three or six degrees of freedom. Moreover, the spindle tilt is limited to very small angles. The advantages of parallel kinematics structures are high precision, lower fabrication cost, good dynamics and high stiffness. This dissertation proposes a systematic configuration design method for the development of new parallel kinematics structures. The parallel structures obtained with this method combine large spindle tilt angles with the advantages of parallel kinematics structures. First, components and characteristic elements of parallel structures are defined and the description of a proposed systematic method for configuration design, the "Design Cube Method", follows. The method enables the design of a family of parallel structures with a specified number and arrangement of mobilities. Methods such as "Gruebler's Formula" and the "Method of Intersecting Trajectories" serve to quickly verify the desired number of degrees of freedom of the structure and the optimal arrangement of the kinematic chains. Several mechanisms are described, that once integrated in a parallel structure, significantly increase the range of tilt of the end-effector, while keeping the stiffness as constant and as high as possible. A new parallel kinematics structure for a five-axis machine-tool has been developed using the new design methods described above. The performance specifications are listed, the desired arrangement of the axis is described and the design cube method is used to generate a new family of parallel kinematics structures. The various structures are evaluated in terms of how suited they are for machine-tool applications, and of the ease of integration of a mechanism to improve the tilt of the end-effector. A laboratory mock-up, demonstrating the various principles, and an industrial prototype of the new machine, the Hita-PDR, have been developed and fabricated. The bar lengths of the structure were selected so as to avoid singularities of the structure in the desired workspace. The specified high stiffness of the industrial prototype required the development of a new type of joint, the simple and double spherical joints with line contact. The high performances of the industrial prototype confirm the machine concept and the relevant choice of the parallel kinematics structure. This dissertation gives a global vision, of the various stages in the design of parallel kinematics structures with large rotations of the end-effector and high stiffness, starting with initial specifications, all the way up to the detailed design and manufacturing of the machine.

EPFL2004

Calibration of high-precision flexure parallel robots

Nuno Ricardo Fazenda Carrico

Over the last decades, calibration techniques have been widely used in robotics since they represent a cost-effective solution for improving the accuracy of robots and machine-tools. They only involve software modification without the necessity of revising the robot design or tightening the manufacturing tolerances. The goal of this thesis is to propose a procedure that guides the engineer through the calibration of a given multi-DOF flexure parallel robot within sub-µm accuracy. Two robots having 3 and 6 degrees of freedom have been considered as a case-study throughout the work. As in any calibration procedure, the work has been conducted on three different fronts: measurement, data processing and validation. The originality of this thesis in respect to published material lies in these three points. Measurements were carried out in a chamber inside which the measuring environment was protected against mechanical and thermal perturbations. In particular, the temperature variations experienced by the different parts of the measuring loop during a typical measurement session were stabilized within less than ± 0.1 °C. Proposed procedures allow the collection of reliable sets of data on the two robots. Delicate aspects of practical implementation are discussed. In particular, the problem of collecting a complete set of 6D data within accuracies in the nanometre range, for which there is still a lack of standard equipment, is solved using a procedure comprising several steps and making use of existing instrumentation. Suggestions for future investigations are given, regarding either long-term research problems or short-term industrial implementation issues. Data processing was performed using two different techniques in order to reach absolute accuracies after calibration better than ± 100 nm for translations and ± 3 arcsec for rotations (± 0.3 arcsec inside a more restricted range of ± 0.11°). The first method is called the "model-based approach" and requires the use of a known analytical relationship between the motor and operational coordinates of the robot. This relationship involves a certain number of parameters that can be related to the geometry of the robot (physical models) or simply mathematical coefficients of an approximating mathematical function (behavioural models). In the case of high-precision multi-DOF flexure parallel robots, we show that polynomial-based behavioural models are preferable to physical models in terms of accuracy for data processing tasks. In the second method, called the "model-free approach", the user does not need to model explicitly the main error sources (or their effect) affecting the robot accuracy. A model-free approach has been implemented using Artificial Neural Networks. We show that, using a heuristic search based on a decision-tree, the architecture of a network with satisfactory prediction capability can be found systematically. In particular, this algorithm can find a network able to predict the direct correspondence between the motor and operational coordinates (within the desired accuracy) without the help of the Inverse Geometric Model of the robot, i.e. even if the nominal geometry of the robot being calibrated remains unknown. This result contradicts conclusions reported by previous researchers. It is claimed that any robot (not necessarily a high-precision flexure parallel mechanism) can be calibrated by means of a "neural approach" in which the architecture of an appropriate network is determined with the help of our algorithm. Two examples (other than the robots measured in this thesis) are given to illustrate this universality. In the last part of this work, we provide a feasibility study on the use of indentation, a technique traditionally used for material testing, as a validation procedure to assess the accuracy of the calibrated degrees of freedom. The industrial interest of this technique lies in the fact that the robot is asked to execute similar motions to those involved in a real micro-machining operation.

EPFL2007