AVEEN M B

Calibration Sales & Support Engineer

Ballbar Measurements

Renishaw QC20-W

COMPANY ORIGIN Research & Development

Sir David McMurtry

Chairman &Chief Executive

John Deer
Deputy Chairman

Formed in 1973 by Sir David McMurtry and John Deer

Originated from a measurement problem at Rolls Royce, Bristol,UK

Founded on innovation in metrology

Global sales & support network

51 locations in 30 countries
+ >60 distributors in 45 countries

First touch-trigger probe invented in 1973 to measurement fuel pipes for the
Olympus (Concorde) jet engine

Organic growth sustained by patented innovations

490 million turnover, 94% exported

18% of turnover spend on R&D and engineering

18 Queens Awards for Enterprise and Innovation

Research & Development

research and development has always

been at the heart of our business

18% turnover on R&D

26% of workforce

Patent protection

Locations: New Mills

Old Town Woodchester

Edinburgh

France

Renishaw India
Head Office Sales & Marketing
Offices
Resident sales Engineers

Chandigarh

Application/Technical support

Gurgaon
Dehradun

Vadodara

Pune
Hyderabad
Bangalore

Chennai
Coimbatore

Kolkata

Agenda
What Are Your Machine Requirements?

QC20 Ballbar System

What is the QC20 Ballbar
Why use a Ballbar
The test process
Results & Error Diagnosis

Accessories
New software features4/23/2016
Slide 6

Volumetric Measurements

What Are Your Machine Tool Requirements?

4/23/2016
Slide 7

What Are Your Machine Tool Requirements?

4/23/2016
Slide 8

Machine Tool Positional and Contouring Errors

Scale Errors

Controllers

Dynamic
Cutting speed

Backlash

Cyclic error

Stick slip

Servo mismatch

Feedrate

Linear

Vibration

Feedrate

Rotary

Cutting forces

Reversal spikes

M/C Errors
Local heat

Straightness
Contamination

Temperature

4/23/2016Environment
Slide 9

Squareness

Flatness

Humidity
Thermal radiation

Lateral play

Peaks

Vibration

Rigidity

Troughs

Foundation

Lighting

Build quality

Geometry

Mass

Structural stiffness

Machine Tool Verification and Calibration

Linear accuracy and
Dynamic
repeatabilityCutting
of an axis
speed

Scale Errors

Controllers

Backlash
Servo mismatch

Cyclic error

Stick slip

Linear

QC20 ballbar

Feedrate

Feedrate

Angular pitch and

yaw of an axis

Vibration

Rotary

Cutting forces

Straightness of an axis

Reversal spikes

M/C Errors
Local heat

Temperature

Straightness
Contamination
Squareness
between axes

Vibration

Rotary axis angular

positioning

Troughs

Rigidity
XL80 LASER

Foundation

MachineLighting
dynamic
characteristics
4/23/2016Environment
Slide 10

Squareness

Flatness

Humidity
Thermal radiation

Lateral play

Peaks

Build quality

Geometry

Mass

Structural stiffness

QC20 Ballbar
A verification device for a range of machine tools
Very quick and simple test (Typically 10 minutes)
Diagnoses twenty machine tool errors
Volumetric verification
Test any 2 linear axes XY YZ ZX
Software - simple to use and very powerful
Use to identify machine faults

Use to Bench-mark machine capability

4/23/2016
Slide 11

Gives an early warning of potential problems

Who Needs the Ballbar system

Production Department
Checking machines are capable of
producing parts to drawing specifications before you start cutting
Machine performance quickly validated after a crash
Monitor machine tool performance
Match accurate work to accurate machines

4/23/2016
Slide 12

Who Needs the Ballbar system

Maintenance Department
Planned maintenance program,
rather than fire fighting!
Early warning of potential problems
Make quick adjustments to improve machine performance

4/23/2016
Slide 13

Who Needs the Ballbar system

Quality Department
Checking machines are capable of producing parts
to drawing specifications - before you start cutting
Comply with ISO 230-4 to help achieve & maintain ISO 9001
Pre-process control will eliminate the machine as an error source
The machine?

The CMM?

The Part Program?

The fixture or clamping?

The Operator?
4/23/2016
Slide 14

QC20 Ballbar Test

Perform 1 Clockwise &
1 Anti-clockwise circles
Select test size to reflect typical part size
Select test area typical working area

Choose feedrate typical finishing feedrate

4/23/2016
Slide 15

QC20-W key specification overview

Working Principle : (Linear Variable Displacement Transducer)
L.V.D.T

4/23/2016
Slide 16

Nominal ballbar length = 100 mm

Measuring range = 1mm
Transducer stroke = -1.25 mm + 1.75 mm
System measurement accuracy (at 20 oC) = 1.0 m
Resolution = 0.1 m
Noise <0.1 m
Max. sample rate = 1000 readings / sec (250 current) (enables full
target data points , even for small, high feed rate circles)
Data transmission range (Class 2 Bluetooth) = 10m typical
Battery life with CR2 standard (non-rechargeable) battery is
minimum of 11hrs continuous use (testing showing up to 600 3min
tests ,30hrs)

Result - Percentages Graph

4/23/2016
Slide 17

Result - Diagnostic Table

4/23/2016
Slide 18

Identify and rank errors

Decide on corrective action depending on error type

4/23/2016
Slide 19

Step 3 - identify and rank errors

Decide on corrective action depending on error type

CB

CB

CB /CL

CL /R

CL

CB - COMPENSATE WITH BALLBAR

4/23/2016
Slide 20

CL - COMPENSATE WITH LASER

R - REPAIR

Error Analysis
Backlash Physical lost motion in the axis
of travel during change of direction. This
will have a direct affect on positioning and
contouring ability.

4/23/2016
Slide 21

Error Analysis
Reversal Spikes - The dwell in the
change in direction of the axis that the
servo is driving. This will have a direct
affect on contouring ability.

4/23/2016
Slide 22

Error Analysis
Servo Miss-match This is caused by
one axis servo moving faster than the other
causing an oval shaped movement of the
axis. As the test is done in both directions
we can distinguish it from a squareness
error. This will have a direct affect on
contouring ability.

4/23/2016
Slide 23

Planes being tested

Value given by
software

Leading axis

XY

+ve

Y leads X

XY

-ve

X leads Y

ZX

+ve

X leads Z

ZX

-ve

Z leads X

YZ

+ve

Z leads Y

YZ

-ve

Y leads Z

Error Analysis
Cyclic Error The run-out of the ballscrew
caused by a drunk ballscrew, or
eccentricity of the ballscrew or encoder
mountings. This will have a direct affect on
positioning and contouring ability.

4/23/2016
Slide 24

Error Analysis
Scaling error Here one axis is moving a
different distance to the other. A reason for
this is wear in the ballscrew and can be
cured by pitch error compensation using
XL80 / ML10. This will have a direct affect
on positioning ability.

4/23/2016
Slide 25

Error Analysis
Straightness This indicates the condition
of the guideways of the machine. It can
show the guides to be bent possibly due to
a crash or worn in the normal working area
of the machine. This will have a direct
affect on positioning and contouring ability.

4/23/2016
Slide 26

Error Analysis
Lateral Play The slop in the axis
guideways of the machine also known as
yaw. This will have a direct affect on
positioning and contouring ability.

4/23/2016
Slide 27

Error Analysis
Squareness This is simply the out of
square to each other of the two axes being
tested. This condition is unaffected by the
federate of the test. This will have a direct
affect on positioning and contouring ability.

4/23/2016
Slide 28

360 Lathe Adapter

Adding the 360 degree
adapter to the standard
kit allows testing of CNC
Lathes

4/23/2016
Slide 29

VTL Adapter
Allows testing of any 2 axis
CNC machine tool
Special retractable centre-mount
Example applications include :- Vertical turning lathes
- Laser cutting machines
- Pick & place machines
- Wire eroding machines
4/23/2016
Slide 30

Small Circle Adapter

Allows testing
of shorter axis
machines
Enables
enhanced
machine servo
analysis

Increases
confidence in
machine tool
performance
4/23/2016
Slide 31

Result - Percentages Graph

4/23/2016
Slide 32

Error Simulation Software

Ballbar result
-1.74ms Servo error
Circularity = 111um

If servo error is removed

Circularity = 57um
Predict the Machine
Improvements that could
4/23/2016
Slide 33

be made in advance

Ballbar History
Schedule regular tests
to spot drift and
deviation

View results from a

series of tests for any
parameter
Apply Pass, Warning
& Fail Tolerance Bands

4/23/2016
Slide 34

QC20-W key specification overview

Nominal ballbar length = 100 mm
Measuring range = 1mm
Transducer stroke = -1.25 mm + 1.75 mm
System measurement accuracy (at 20 oC) = 1.0 m
Resolution = 0.1 m
Noise <0.1 m
Max. sample rate = 1000 readings / sec (250 current) (enables full
target data points , even for small, high feed rate circles)
Data transmission range (Class 2 Bluetooth) = 10m typical
Battery life with CR2 standard (non-rechargeable) battery is
minimum of 11hrs continuous use (testing showing up to 600 3min
tests ,30hrs)

4/23/2016
Slide 35

The Machine Performance Measurement Cycle

Bench mark

Calibrate

Benchmark with a
Ballbar test

Fix

Monitor

MADE IN U.K

SCALE

0.9997

Verify
27

4/23/2016
Slide 36

QC20 Ballbar And Calibration

Eliminates judgement calls
- which machine can run which parts?
Eliminates bottlenecks on the good machines
Protects investment of prior operations
Increases machine up-time by reducing machine
downtime due to maintenance troubleshooting
Eliminates unnecessary movement
of parts throughout the shop

4/23/2016
Slide 37

Provides traceable documentation

of process capability

Maximising Your Manufacturing Process

Eliminate Waste - Rework & Scrap
Improve Quality - Winning new contracts
Improve Productivity - Protect machined in value
Saving you Money

4/23/2016
Slide 38

Thank You
4/23
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Slid
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apply innovation