An error compensation method for on-machine measuring blade with industrial robot

To achieve the seamless integration of precision grinding blade with timely measured data, an on-machine measurement system employing industrial robot is developed. The limitation to its widespread application lies in the accuracy of measurement, prompting the proposal of an error compensation method to address the measurement error within the implemented blade on-machine measurement system. To address the pre-travel error in the measuring device of the on-machine measurement system, an analysis of the factors influencing the pre-travel error of the contact probe is conducted. Subsequently, pre-travel error data is gathered utilizing the experimental calibration method involving a standard ball, and a prediction model employing the bilinear interpolation algorithm is established to facilitate error compensation. Employing pre-travel error compensation for the analysis of the operating body error in the on-machine measurement system, a spherical center distance constraint error model is derived through closed-loop kinematic calibration of the six-degrees-of-freedom industrial robot. Kinematic parameter error identification is conducted using a hybrid algorithm combining the L-M algorithm and the adaptive factor double-variable DE algorithm. This approach diminishes the spherical center distance measurement error, reducing it from 0.081 mm to 0.016 mm. Subsequently, experiment is conducted to measure blade machining allowances using an on-machine robotic measurement system, comparing the obtained data with measurement from a blue light scanner and a coordinate measuring machine (CMM). The results reveal average absolute deviations of 0.020 mm, 0.015 mm, and 0.016 mm in the three blade cross sections for the on-machine robotic measurement system and the blue light scanner, respectively. Correspondingly, the average absolute deviations for the on-machine robotic measurement system and the CMM in the three blade sections are 0.028 mm, 0.029 mm, and 0.029 mm. Moreover, the on-machine measurement system demonstrates commendable measurement repeatability, with a standard deviation of 0.003 mm.