Novel position measurement and estimation methods for CNC machine systems

Kılıç, Ergin
Precision control of translational motion is vital for many CNC machine tools as the motion of the machinery affects the dimensional tolerance of the manufactured goods. However, the direct measurement along with the accurate motion control of machine usually requires relatively expensive sensors i.e. potentiometers, linear scales, laser interferometers. Hence, this study attempts to develop reference models utilizing low-cost sensors (i.e. rotary encoders) for accurate position estimation. First, an indirect measurement performance is investigated on a Timing Belt driven carriage by a DC Motor with a backlash included Gearbox head. An advanced interpolated technique is proposed to compensate the position errors while using indirect measurement to reduce the total cost. Then, a similar study was realized with a ball screw driven system. Next, a cable drum driven measurement technique is proposed to the machines which have long travel distance like plasma cutters. A test setup is proposed and manufactured to investigate the capstan drive systems. Finally, characteristics of Optical Mouse Sensors are investigated from different point of views and a test setup is proposed and manufactured to evaluate their performances in long terms. Beside all of these parts, motion control algorithms and motion control integrated circuits are designed and manufactured to realize experimental studies in a detailed manner.


"High precision CNC motion control"
Ay, Gökçe Mehmet; Dölen, Melik; Department of Mechanical Engineering (2004)
This thesis focuses on the design of an electrical drive system for the purpose of high precision motion control. A modern electrical drive is usually equipped with a current regulated voltage source along with powerful motion controller system utilizing one or more micro-controllers and/or digital signal processors (DSPs). That is, the motor drive control is mostly performed by a dedicated digital-motion controller system. Such a motor drive mostly interfaces with its host processor via various serial comm...
Computer aided manufacturing (CAM) data generation for solid freeform fabrication
Yarkınoğlu, Onur; Koku, Ahmet Buğra; Department of Mechanical Engineering (2007)
Rapid prototyping (RP) is a set of fabrication technologies that are used to produce accurate parts directly from computer aided drawing (CAD) data. These technologies are unique in a way that they use an additive fabrication approach in which a three dimensional (3D) object is directly produced. In this thesis study, a RP application with a modular architecture is designed and implemented to satisfy the possible requirements of future rapid prototyping studies. After a functional classification, the develo...
Development of a stereo vision system for an industrial robot
Bayraktar, Hakan; Kaftanoğlu, Bilgin; Department of Mechanical Engineering (2004)
The aim of this thesis is to develop a stereo vision system to locate and classify objects moving on a conveyor belt. The vision system determines the locations of the objects with respect to a world coordinate system and class of the objects. In order to estimate the locations of the objects, two cameras placed at different locations are used. Image processing algorithms are employed to extract some features of the objects. These features are fed to stereo matching and classifier algorithms. The results of...
Modeling and simulation of a navigation system with an IMU and a Magnetometer
Kayasal, Uğur; Özgören, Mustafa Kemal; Department of Mechanical Engineering (2007)
In this thesis, the integration of a MEMS based inertial measurement unit and a three axis solid state magnetometer are studied. It is a fact that unaided inertial navigation systems, especially low cost MEMS based navigation systems have a divergent behavior. Nowadays, many navigation systems use GPS aiding to improve the performance, but GPS may not be applicable in some cases. Also, GPS provides the position and velocity reference whereas the attitude information is extracted through estimation filters. ...
A programmable control unit for industrial applications
Güngör, Mustafa Kemal; Hızal, Mirzahan; Department of Electrical and Electronics Engineering (2003)
In this thesis, the automation of the long term and cyclic processes by using a programmable control unit is aimed. To achieve this goal, timing relays and various microcontrollers are investigated. PIC microcontroller is chosen to implement the control unit due to its advantages like high speed, Harvard and RISC architecture, low cost and flexibility for programming. Theory of the PIC microcontrollers is studied and a controller unit to be used in the mentioned processes is designed. Some features are adde...
Citation Formats
E. Kılıç, “Novel position measurement and estimation methods for CNC machine systems,” M.S. - Master of Science, Middle East Technical University, 2007.