2005년 대한 생화학·분자생물학회 하계학술대회를 다녀와서

Intelligent spindles are core components of the next-generation of intelligent/smart machine tools in the Industry 4.0 Era. The purpose of this paper is to clarify the concept of intelligent spindles and provide an in-depth review of the state-of-the-art of related technologies. A new integrated concept for intelligent spindles is proposed, followed by descriptions of required characteristics, key enabling technologies and expected intelligent functions. Relevant research that may be beneficial to the development of intelligent spindles is reviewed from six thrust areas, which include monitoring and control of tool condition, chatter, spindle collision, temperature/thermal error, spindle balance, and spindle health. Finally, current limitations and challenges are discussed, and future trends of intelligent spindles are prospected from various perspectives.

The concept and progress of intelligent spindles: A review

Thermal error, especially the one caused by the thermal expansion of spindle in axial direction, seriously impacts the accuracy of the precision machine tool. Thermal error compensation based on the thermal error model with high accuracy and robustness is an effective and economic way to reduce the impact and enhance the accuracy. Generally, thermal error models are built only on temperatures at some points in the spindle system. However, the thermal error is also closely related to other working parameters. Through the theoretical analysis, the simulation, and the experimental testing in this paper, it is found out that thermal error is determined by multiple variables, such as the temperature, the spindle rotation speed, the historical spindle temperature, the historical thermal error, and the time lag between the present and previous times. In order to examine the performance of thermal error models based on multiple variables, two common methods are used for modeling—the multiple regression method and the back propagation network. The data for modeling are collected from experiments conducted on the spindle of a precision machine tool under various working conditions. The modeling results demonstrate that models established based on the multiple variables have better accuracy and robustness. It also turns out that data filtering before modeling can further improve the performance of the models. Therefore, models based on multiple variables with good accuracy and robustness can be very useful for the further thermal error compensation. In addition, by taking relative importance analysis of multiple variables based on standardized regression coefficients, the influence of each variable to the thermal error is revealed. The ranking of coefficients can also be used as a new criterion for the optimal temperature variable selection in the future research.

Thermal error modeling of the spindle based on multiple variables for the precision machine tool

Among the thermal error sources of the high accuracy and efficiency machine tools, the thermal errors induced by the heat generated from running high speed motorized spindle is the crucial one. A new thermal error control method for motorized spindle is suggested, which is based on the thermal deformation balance principle. The essential idea of the method is to utilize the thermal contraction of Carbon Fiber Reinforced Plastic (CFRP) to restrain the thermal elongation of metal spindle housing. In the designed control system, the CFRP bars are uniformly distributed around the spindle housing, and the ThermoElectric Modules (TEMs) works as the heat pump which transfers the heat from spindle housing to CFRP bar. The experimental and numerical simulation results show that the suggested approach reduces 97% thermal displacement compared with the motorized spindle without the suggested thermal error control system. It is expected that the suggested method can also be applied to thermal error control for various cylindrical high-precision parts including aerospace equipment, optics and optical instruments.

Design of thermal error control system for high-speed motorized spindle based on thermal contraction of CFRP

The temperature rise of an ultra-precision machine tool has a great impact on machining accuracy. Meanwhile, the hydrostatic spindle system is the main internal heat source of the machine tool, which consists of a hydrostatic spindle and a direct current motor. Therefore, it is very significant to study the thermal behaviors of the hydrostatic spindle system. In this paper, an integrated heat-fluid–solid coupling model of the hydrostatic spindle system is built to simulate the heat generation process and the fluid–structure conjugate heat transfer. Then a finite volume element method (FVEM) is proposed by combining the advantages of the finite volume method (FVM) and the finite element method (FEM) with consideration of the interaction of the temperature field, thermal deformation, and eccentricity. Based on the proposed model and method, the thermal characteristics of the hydrostatic spindle system are studied by the two-way heat-fluid–solid coupling analysis. The temperature variations obtained by the simulation agree well with the experimental results, which validate the proposed model and method.

Thermal analysis of the hydrostatic spindle system by the finite volume element method

The errors which affect the processing tolerance of a machine tool are due to the built-in volumetric errors in the machine tool structure and also the thermal displacement of the machine tools during its cutting. In this paper, a dual-displacement meter compensation system is developed. The new model has a better tolerance control than the single-displacement compensation meter method; also, it has a great potential for saving a machine’s warm-up time as well as enhancing productivity. A dual-displacement meter is designed to detect the variation of spindle thermal growth and a differential amplifier is applied which ensure a precise output signal tolerance of spindle thermal growth. The unstable signal which is an effect of flatness tolerance of spindle surface is then omitted. Finally, the spindle thermal growth compensations are successfully reduced. It meets the requirement of high-speed machining and high-precision machining application.

/pdf/thermal-growth-measurement-and-compensation-for-integrated-1p4mve4l87.pdf

Thermal growth measurement and compensation for integrated spindles

This paper proposes an intelligent monitoring system to adapt motorized high speed spindle on machine tools to meet the requirement of Industries 4.0, based on the techniques of power electronic engineering, mechatronics and reliability engineering. In this paper, a force-sensor-integrated spindle is proposed to monitor the bearing stress during operation. The implementation of charge amplifier and mechanical design are described as well. As a result, raw data is transmitted through a filter to create fruitful information and allow the remote monitoring system to operate effectively. The information supports predictive maintenance plans and improves the quality of after-sales service.

/pdf/study-of-motorized-spindle-reliability-monitoring-eub905hnqw.pdf

Study of Motorized Spindle Reliability Monitoring

A spindle control system for a milling machine is provided. The milling machine includes a column, an overarm, a spindle for mounting a cutter, a first motor mounted on the column for driving movement of the overarm, and a second motor mounted on the overarm for driving rotation of the spindle. The spindle control system includes a distance sensor and a temperature sensor, each to be mounted on the overarm and to be disposed proximate to the end portion of the spindle. The spindle control system further includes a central control unit for determining a compensation parameter based on the displacement sensed by the distance sensor and the temperature sensed by the temperature sensor, and for controlling movement of the overarm by the first motor through a compensation distance based on the compensation parameter to compensate for at least one of the cutter deformation and the spindle deformation.

Spindle control system for a milling machine

A milling machine has a base, a work platform mounted movably on the base, and a ruler mounted on the work platform. The work platform is movable relative to a base axis. The thermal compensation system includes a sensor and a control unit. The sensor is configured to be mounted on the base for sensing a position of each of the work platform and the ruler relative to the base axis. The control unit is coupled to the sensor, and determines a work platform displacement and a ruler displacement according to the positions sensed by the sensor. The control unit further calculates a compensation value based on the work platform displacement and the ruler displacement. The control unit is configured to correct the position of the work platform relative to the base axis according to the compensation value.

Thermal compensation system for a milling machine

A control system of a milling machine is disclosed. The milling machine has an overarm, a spindle connected to a cutter, a spindle motor, and an X-axis motor, a Y-axis motor and a Z-axis motor. The control system includes a vibration sensor for detecting a vibration level of the spindle. The control system also includes a central control unit configured to adjust a rotation speed of at least one of the X-axis motor, the Y-axis motor, and the Z-axis motor to bring a load current of at least one of the motors to be within a corresponding current range, and configured to adjust a rotation speed of the spindle motor to bring the vibration level to be within a vibration range.

Control system of milling machine

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