Geometric errors of five-axis machine tool should be fully compensated in real-time to ensure the compatibility and reduce the residual error of the strategy. To achieve this purpose, this paper proposes a real-time complete geometric error compensation strategy, which compensates the influences of all geometric error components with explicit and compact solutions suitable for online execution. Typical characteristic of this strategy lies in the following three aspects. First, all geometric error components including position independents geometric errors and position dependent geometric errors are compensated. Residual errors induced by existing sub-optimal methods, such as Jacobian matrix based methods and sensitivity analysis based methods, are avoided. Second, explicit and compact solutions for compensation motion commands to counteract the influences of geometric errors are given. Commutative law of error motion matrixes, commutative law of translational motion matrixes and decomposition feature of translational motions are exploited and verified. Based on these discoveries, the compensation motion commands are integrated into compact and simple algebra forms, which can be solved in real-time compared to formula-expansion based methods and iterative-calculation based methods. Third, the proposed strategy is suitable for five-axis machine tool with arbitrary configurations. Through introducing the local coordinate system transition principle, the established algebra forms of compensation motion commands can be directly suited for machine tools with non-orthogonal rotary axes. Thus, additional derivation procedure as required by existing methods is avoided. Simulation results verify the effectiveness, feasibility and universality of the proposed strategy. Experimental results confirm that the machined workpiece has a remarkable precision improvement by using the proposed compensation method.
Liu et al. (Wed,) studied this question.