Key point selection in large-scale FBG temperature sensors for thermal error modeling of heavy-duty CNC machine tools

Abstract

Thermal error is one of the main factors that influence the machining accuracy of computer numerical control (CNC) machine tools. It is usually reduced by thermal error compensation. Temperature field monitoring and key temperature measurement point (TMP) selection are the bases of thermal error modeling and compensation for CNC machine tools. Compared with small- and medium-sized CNC machine tools, heavy-duty CNC machine tools require the use of more temperature sensors to measure their temperature comprehensively because of their larger size and more complex heat sources. However, the presence of many TMPs counteracts the movement of CNC machine tools due to sensor cables, and too many temperature variables may adversely influence thermal error modeling. Novel temperature sensors based on fiber Bragg grating (FBG) are developed in this study. A total of 128 FBG temperature sensors that are connected in series through a thin optical fiber are mounted on a heavy-duty CNC machine tool to monitor its temperature field. Key TMPs are selected using these large-scale FBG temperature sensors by using the density-based spatial clustering of applications with noise algorithm to reduce the calculation workload and avoid problems in the coupling of TMPs for thermal error modeling. Back propagation neural network thermal error prediction models are established to verify the performance of the proposed TMP selection method. Results show that the number of TMPs is reduced from 128 to 5, and the developed model demonstrates good prediction effects and strong robustness under different working conditions of the heavy-duty CNC machine tool.

Key words： thermal error; heavy-duty CNC machine tools; FBG; key TMPs; prediction model

Acknowledgements

The authors would like to acknowledge the financial support provided by the National Natural Science Foundation of China (Grant Nos. 51475347 and 51475343) and the International Science and Technology Cooperation Program of China (Grant No. 2015DFA70340). The contributions of all collaborators in the mentioned projects are also well-appreciated.

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