Decentralized structure-integrated spatial force measurement in machine tools

New manufacturing processes and extended movability of modern machine tools, such as five-axis kinematics or hexapods, increase the demand for in-process measurement of spatial forces and torques in up to 6 degrees of freedom (DoF). The approach proposed in this paper is based on the idea of integrating 6 single-axis force sensors into the machine's structure and converting these sensor forces to spatial forces and torques at the tool centre point (TCP) using a measurement model. This concept is advantageous to costs, ruggedness and available workspace when compared to state-of-the-art 6 DoF force/torque transducers. At the same time, the achievable measuring accuracy is similar and also significantly better than the accuracy of drive current based force evaluation. On the other hand, structure and machine influences have to be addressed by suitable measurement models. This article presents design, parametrization, verification, and characterisation of these measurement models on the example of four integration concepts, two in rigid bar frameworks and two in bar kinematics. Further, experimental results are shown which are classified in comparison to a 6 DoF F/T sensor and drive current based force measurement. Finally, other influences, such as structural design and deformations, as well as the integration of sensors and models into the machine's control software are discussed.