Method and apparatus for self-calibrating a motion control system

• US 6,859,747 B2
• Filed: 04/17/2002
• Issued: 02/22/2005
• Est. Priority Date: 04/26/2001
• Status: Expired due to Term

• Current Assignee: Siemens Industry Incorporated (Siemens AG)
• Original Assignee: Siemens Energy & Automation Incorporated (Siemens AG)
• Inventors: Yutkowitz, Stephen J.
• Primary Examiner(s): Barlow, John
• Assistant Examiner(s): BHAT, ADITYA S
• Application Number:
  US10/124,003
• Publication Number:
  US 20030033105A1
• Time in Patent Office: 1,042 Days
• Field of Search: 702/95, 702/105, 318/568.1, 318/569, 318/638, 318/571, 318/568.18, 318/616, 700/37, 356/498
• US Class Current: 702/105
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 2219/39015 With different manipulator configurations, contact known sphere, ballbar
• CPC Class Codes: G05B 2219/50139 Calibration, setting tool after measurement on tool

Abstract

In one embodiment, a method of and apparatus for self-calibrating a motion control system is provided. The method includes the steps of receiving a test parameter, ensuring a reasonable test can be executed based on the test parameter, generating a part program based upon the test parameter, instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test, and executing the test, wherein the part program is executed as part of the test.

Claims

1. A computer readable medium comprising instructions capable of implementing a method of self-calibrating a motion control system, the method comprising:

receiving a test parameter;

ensuring a reasonable test can be executed based on the test parameter;

generating a part program based upon the test parameter;

instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

executing the test, wherein the part program is executed as part of the test; and

wherein the act of ensuring a reasonable test can be executed comprises ensuring a reasonable ballbar circle test can be executed.

2. A machine tool, comprising:

a) an actuator having an attached mechanical member;

b) a motion command generator adapted to produce motion commands capable of controlling the actuator;

c) a compensator adapted to compensate the motion commands based upon at least one compensation parameter; and

d) a controller in communication with the actuator, the motion command generator, and the compensator, and adapted to;

i) receive a test parameter;

ii) ensure a reasonable test can be executed based on the test parameter;

iii) generate a part program based upon the test parameter;

iv) instruct a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

v) execute the test, wherein the part program is executed part of the test; and

wherein the act of ensuring a reasonable test can be executed comprises ensuring a reasonable ballbar circle test can be executed.

3. A method of self-calibrating a motion control system comprising:

receiving a test parameter;

ensuring a reasonable test can be executed based on the test parameter;

generating a part program based upon the test parameter;

instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

executing the test, wherein the part program is executed as part of the test;

wherein

the act of ensuring a reasonable test can be executed comprises ensuring a reasonable ballbar circle test can be executed.

5. The method of claim 3, further comprising the act of indicating a problem if a reasonable test cannot be executed.

6. The method of claim 3, further comprising requiring a change in the test parameter if a reasonable test cannot be executed.

7. The method of claim 3, wherein the act of instructing a user comprises providing a test interface capable of instructing a user regarding setting up and executing the test.

8. The method of claim 7, wherein the act of providing a test interface further comprises indicating progress in each of a series of tasks comprising test.

9. The method of claim 8, wherein the act of indicating progress further comprises returning to a previous one in the series of tasks when a current one in the series of tasks fails to be completed.

10. The method of claim 9, wherein the act of providing a test interface further comprises providing a description of which one in the series of tasks to perform next.

11. The method of claim 3, further comprising analyzing the test.

12. The method of claim 11, further comprising displaying analysis of the test.

13. The method of claim 11, further comprising analyzing an affect of manipulating a parameter of the motion control system that is configured to compensate for a condition to which the test is related.

14. The method of claim 3, further comprising changing a parameter of the motion control system that is configured to compensate for a condition to which the test is related.

15. The method of claim 14, wherein the act of changing a parameter comprises:

providing an adjustment interface capable of receiving a change to the parameter; and

if received, implementing the change to the parameter.

16. The method of claim 15, wherein the act of changing a parameter further comprises suggesting the change to the parameter.

17. The method of claim 15, wherein the act of changing a parameter further comprises displaying a significance of the parameter.

18. The method of claim 3, wherein the act of ensuring a reasonable test can be executed comprises ensuring the part program is within the capabilities of machine controlled by the motion control system and is capable of providing results that can be used to tune a compensation parameter.

19. The method of claim 3, wherein the act of ensuring a reasonable test can be executed comprises emulating execution of at least a portion of the part program.

20. The method of claim 19, wherein the act of emulating execution comprises running portions of the part program through motion algorithms of the motion control system, wherein a machine controlled by the motion control system does not have to be actuated to ensure a reasonable test can be executed.

21. The method of claim 19, wherein the act of emulating execution comprises running the emulation as a callable function in a non-real time environment associated with the motion control system.

22. The method of claim 3, wherein the act of instructing a user further comprises instructing a user with respect to executing the test.

43. The method of claim 3, wherein the act of receiving a test parameter comprises the act of providing a setup interface capable of allowing a user to select a test parameter.

4. A method of self-calibrating a motion control system comprising:

receiving a test parameter;

ensuring a reasonable test can be executed based on the test parameter;

generating a part program based upon the test parameter;

instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

executing the test, wherein the part program is executed as part of the test;

wherein at least one of the act of instructing a user and the act of executing the test comprises using a finite state machine to coordinate progression through tasks associated with the at least one of the acts.

23. The method of claim 4, further comprising the act of indicating a problem if a reasonable test cannot be executed.

24. The method of claim 4, further comprising requiring a change in the test parameter if a reasonable test cannot be executed.

25. The method of claim 4, wherein the act of instructing a user comprises providing a test interface capable of instructing a user regarding setting up and executing the test.

26. The method of claim 25, wherein the act of providing a test interface further comprises indicating progress in each of a series of tasks comprising the test.

27. The method of claim 26, wherein the act of indicating progress further comprises returning to a previous one in the series of tasks when a current one in the series of tasks fails to be completed.

28. The method of claim 27, wherein the act of providing a test interface further comprises providing a description of which one in the series of tasks to perform next.

29. The method of claim 4, further comprising analyzing the test.

30. The method of claim 29, further comprising displaying analysis of the test.

31. The method of claim 29, further comprising analyzing an affect of manipulating a parameter of the motion control system that is configured to compensate for a condition to which the test is related.

32. The method of claim 4, further comprising changing a parameter of the motion control system that is configured to compensate for a condition to which the test is related.

33. The method of claim 32, wherein the act of changing a parameter comprises:

providing an adjustment interface capable of receiving a change to the parameter; and

if received, implementing the change to the parameter.

34. The method of claim 33, wherein the act of changing a parameter further comprises suggesting the change to the parameter.

35. The method of claim 33, wherein the act of changing a parameter further comprises displaying a significance of the parameter.

36. The method of claim 4, wherein the act of ensuring a reasonable test can be executed comprises ensuring the part program is within the capabilities of a machine controlled by the motion control system and is capable of providing results that can be used to tune a compensation parameter.

37. The method of claim 4, wherein the act of ensuring a reasonable test can be executed comprises emulating execution of at least a portion of the part program.

38. The method of claim 37, wherein the act of emulating execution comprises running portions of the part program through motion algorithms of the motion control system, wherein a machine controlled by the motion control system does not have to be actuated to ensure a reasonable test can be executed.

39. The method of claim 37, wherein the act of emulating execution comprises running the emulation as a callable function in a non-real time environment associated with the motion control system.

40. The method of claim 4, wherein the act of instructing a user further comprises instructing a user with respect to executing the test.

41. The method of claim 4, wherein the finite state machine recurrently polls control and measured data associated with the test to determine when a requirement for a transition to a next state in the act of executing the test has been fulfilled.

42. The method of claim 41, wherein the finite state machine controls execution of the part program through the user of messages.

44. The method of claim 4, wherein the act of receiving a test parameter comprises the act of providing a setup interface capable of allowing a user to select a test parameter.

45. A computer readable medium comprising instructions capable of implementing a method of self-calibrating a motion control system, the method comprising:

receiving a test parameter;

ensuring a reasonable test can be executed based on the test parameter;

generating a part program based upon the test parameter;

instructing a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

executing the test, wherein the part program is executed as part of the test;

wherein at least one of the act of instructing a user and the act of executing the test comprises using a finite state machine to coordinate progression through tasks associated with the at least one of the acts.

46. A machine tool, comprising:

a) an actuator having an attached mechanical member;

b) a motion command generator adapted to produce motion commands capable of controlling the actuator;

c) a compensator adapted to compensate the motion commands based upon at least one compensation parameter; and

d) a controller in communication with the actuator, the motion command generator, and the compensator, and adapted to;

i) receive a test parameter;

ii) ensure a reasonable test can be executed based on the test parameter;

iii) generate a part program based upon the test parameter;

iv) instruct a user of the motion control system regarding set up of a device capable of acquiring data associated with the test; and

v) execute the test, wherein the part program is executed part of the test;

wherein at least one of the act of instructing a user and the act of executing the test comprises using a finite state machine to coordinate progression through tasks associated with the at least one of the acts.