Thermal Inaccuracy Modelling &

Compensation Using Real-Time

Data

Prepared By:-
Rathod Ronakkumar
(18540007-Mtech)

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Introduction
 What Is Real Time Data?
 Information that is delivered immediately after
collection.
 Real-time data is often used for navigation or
tracking.

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Thermal Deformation
 When the machine tool is in operation, thermal
deformation is unavoidable because the temperature of
the moving parts of the machine tool is dynamically
changing in the entire process.
 The temperature of machine tool is affected by two
factors, i.e., the internal heat generated from the work
done by the driving motor of the machine tool, and the
external thermal radiation and convention between the
machine tool and the machining environment.

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Methods For Thermal error
Measurement
 1) S. H. Chen :- He built a measurement system of
thermal displacement using intelligent processing
module, and the regression analysis software Minitab is
used to solve the deformation compensation model for
spindle of vertical machining center.

 2) C. Zhang:- presented a novel method for searching

critical thermal points via infrared imaging system and
the system identification of thermal error is conducted
based on least square principle.

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Contd….
 3)Pai-Chung Tseng:- An IC type thermometer is designed
to detect the temperature variation at specific
components of the machine tool. These thermal
displacements are measured on-line with a touch trigger
probe.
 A mathematical model is then built, based on the sensed
temperature variation and the thermal displacements by
multivariable regression analysis.

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Problems In using Previous Methods
 The modelling and compensation of thermal
deformation normally relies on the temperature
retrieved from the sensors embedded or mounted on
the machine tools.
 Thermal deformation estimated in this way is normally
very difficult to be applied in the real machining
application, because on one hand, the installation of
temperature sensors and their accessories are
internally very complex tasks, which could reduce the
working stability of the machine tool.
 on the other hand, with the embedded temperature
sensor, the structure of the machine tool will become
more complicated and thus the manufacturing cost is
increased.

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Solution?
 To overcome deficiencies in reducing the thermal error
for machine tool, this paper proposes a novel method by
modelling the thermal deformation of ball screw as
function of real-time internal data of CNC system (e.g.,
the current, velocity, displacement and so on).
Instead of relying on the temperature sensors, the data is
utilized to as basis of building the model. In this way, the
motion induced thermal deformation of the machine tool
can be estimated precisely.

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Analysis of Thermal deformation
Induced Factors
 The thermal deformation of the machine
tool can be affected by two factors
(1)Working Environment
(2)Frictional Motion Of the Ball Screw

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 With considering the motion of the ball screw and the
change of environmental temperature together, the
thermal deformation could reach as high as 0.08mm in 2.5
hours.

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 When the ball screw works, the heat generated by friction
force in the ball screw could affect the thermal
deformation of the entire ball screw system, and the
greater the load on the ball screw is, the more heat is
generated, and the larger the thermal deformation could
be.

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 Real-time data based thermal
deformation model
 Two models predicting the thermal deformation are
defined respectively for the warming up process and
cooling down state of the machine tool.
 where, for the former, the relationship between
thermal deformation and real-time data of CNC
machine tools is established based on energy
conservation law with the heat production and heat
dissipation considered.
 And for the latter, another model is defined to
characterize the thermal deformation as the
temperature of machine tool gradually decreases.
Based on these two models, the thermal deformation
is then estimated precisely.
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Thermal deformation prediction
model in warming-up process
 The thermal deformation ∆L can be calculated as:

•Parameters In equation Are the heat generated in forward

direction, heat generated in backward direction, heat
dissipation in natural convection and forced convection
heat dissipation respectively.

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Thermal deformation in
cooling down
 Thermal deformation in the cooling down stage
is classic exponent function of time.

 where, is the time of cooling down, ∆L is

thermal deformation of the shaft at the moment ,
A and B are constant values.

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Thermal deformation of ball screw in cooling down stage

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 Parameter identification of
thermal deformation model
 Parameter identification in model of
warming up stage :-
 These parameters are determined by a multiple linear
regression method.
 After simplifying notations in thermal deformation equation

 As matrix form :-

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 The result of Kf from ridge regression is

 k is scalar representing the ridge, which is

solved iteratively as:

 p is the number of prediction variables; Kj(Kl)

is the regression coefficients obtained by least
square method; is the sum of the error
square

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 Parameter identification in model of
cooling down stage:-
 A can be determined by the experimental data,

 Take logarithm on both the left and right side of Eq

 The parameter B in this equation can then be found by

the classical linear regression method

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 Experiments and discussion
 The thermal deformation of the ball screw, the driving
part of a machine tool’s Z axis, is estimated with the
proposed model both for the warming up state and the
cooling down state.
 For the small-size drilling centre DMTG TD- 500A
parameters are

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 In addition to mentioned machine tool, a device called
tool auto-checking instrument is utilized to measure the
thermal deformation
 1) From the cold state of the machine tool, the Z-axis is
continuously moving up and down at a high speed of
24000mm/min, so as to simulate the warming up state of
the machine tool.
 2) After running 2 hours, the machine tool stops and the
ball screw of the machine tool graduate cools down.
 3) The tool auto-checking instrument amounted on the
machine tool is used to measure the thermal
deformation.
 4) The real-time data related parameters the speed of Z-
axis and current of motor, are retrieved from the
Huazhong-8 CNC system with a sampling software SSTT.

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 The data are then used to train the parameters
Kf,Kr,Kz,Kq And A,B in the thermal deformation model.

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Experimental results
 According to the experimental data and the
methods proposed, the identified parameters
are:
 [Kf,Kr,Kz,Kq]=[1.4*10^-5,1.08*10^-7, -3.9*10^-
6, -9.59*10^-7] .
 [A,B]=[0.12 ,6*10^-4].

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22
Conclusions
 1) In the warming up stage, after compensating from the
estimated value, the thermal error of Z-axis, which is mainly
caused by frictional motion, was reduced from 0.051mm to
0.004mm, about a 92% reduction.
 2) In the cooling stage, the estimated value matches the real
measured result very well, and the maximal deviation of the
estimated and real measure value is only 0.01 mm, which is
significantly less than the maximal thermal deformation of
0.13mm
 3)Compared with the traditional methods which rely on the
large amount of temperature sensors embedded in the
machine tool, the proposed methods mainly utilize the real-
time data in the CNC system, and the thermal deformation
of ball screw is predicted precisely. Thus, both the cost for
thermal error compensation and the warming up time of
machine tool is significantly reduced.
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References
 [1] P. C. Tseng, and S. Y. Maui, "Technology of thermal
compensation on a machining center", 12th National
Conference on Mechanical Engineering, CSME, Chia-Yi,
Taiwan, November1995.
 [2] Weck, M., et al., Reduction and Compensation of
Thermal Errors in Machine Tools. CIRP Annals, 1995.
44(2): p. 589- 598.

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Thank You

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