Geometric Error Identification of Gantry-Type CNC Machine Tool Based on Multi-Station Synchronization Laser Tracers

Abstract Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement. We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control (CNC) machine tools. This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method. We consider a three-axis gantry-type CNC machine tool, and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain. The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle. A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg–Marquardt nonlinear least squares method, and the geometric error is solved using Taylor’s first-order linearization iteration. The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer. For a volume of 800 mm × 1000 mm × 350 mm, the maximum differences of the linear, angular, and spatial position errors were 2.0 μm, 2.7 μrad, and 12.0 μm, respectively, which verifies the accuracy of the proposed algorithm. This research proposes a modeling method for the precise measurement of errors in machine tools, and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.