A Comparison of the Probes with a Cantilever Beam and a Double-Sided Beam in the Tool Edge Profiler for On-Machine Measurement of a Precision Cutting Tool

This paper describes a comparison of the mechanical structures (a double-sided beam and a cantilever beam) of a probe in a tool edge profiler for the measurement of a micro-cutting tool. The tool edge profiler consists of a positioning unit having a pair of one-axis DC servo motor stages and a probe unit having a laser displacement sensor and a probe composed of a stylus and a mechanical beam; on-machine measurement of a tool cutting edge can be conducted with a low contact force through measuring the deformation of the probe by the laser displacement sensor while monitoring the tool position. Meanwhile, the mechanical structure of the probe could affect the performance of measurement of the edge profile of a precision cutting tool. In this paper, the measurement principle of the tool edge profile is firstly introduced; after that, slopes and a top-flat of a cutting tool sample are measured by using a cantilever-type probe and a double-sided beam-type probe, respectively. The measurement performances of the two probes are compared through experiments and theoretical measurement uncertainty analysis.

Visually quantifiable test piece for five-axis machine tools thermal effects

Thermal deviation induced by ambient temperature changes and heat generated during machine operations influences the accuracy of machine tools. A thermal test is essential to evaluate the influence of thermal deviation. ISO 230-3 provides displacement sensor-based thermal tests for machine tools. This paper proposes a machining test that enables a user to visually, by the naked eye, observe the integrated thermal influence on the tool trajectory's displacement in the direction normal to the test piece surface from the length of the machined slots. The proposed test consists of the machining of the five surfaces to observe the thermal influence of the tool position with respect to the test piece in X-, Y- and Z-directions, as well as the position of two rotary axes with respect to the tool position. The advantages of the proposed test include that it requires no measuring instrument to quantitatively evaluate the thermal error in all directions. And since the thermal influence is evaluated by observing the position where the cutting tool leaves the test piece surface, where the cutting force is zero, the influence of the cutting force on the test results can be ignored. Thermal influences of a five-axis machine tool during the warm-up cycle are investigated by experiment to validate the feasibility of the proposed method. Results show that 150 min is needed for sufficient warm-up for the selected machine tool if permissible tolerance for thermal deviation is 2.5 um for all the errors.

Enhanced Ball Shear Testing Configuration For Substrate LGA Sensor Devices

Semiconductor assembly mass production environment has means of testing and verifying bond consistency and reliability during wire bonding. Common bond integrity assessment is ball shear testing (BST). This test enables analysis of the strength between the bond pad and a ball bond. This paper presents significant procedure on how ball shear testing parameters should be treated during wirebond integrity check. Device complexity in terms of performing ball shear testing specifically on sensor dice has different output responses. Frequent shearing on die resulted as bond pads are elevated by 30 µm (microns). To address manufacturing in-process controls challenges, shearing tool position, dage settings, and optical scopes are taken into consideration. Also, a study was performed on the execution correctness in combination with proper dage parameters was explored to meet good ball shear test process capability and break modes.

Kalman Filter and Variants for Estimation in 2DOF Serial Flexible Link and Joint Using Fractional Order PID Controller

Robotic manipulators have been widely used in industries, mainly to move tools into different specific positions. Thus, it has become necessary to have accurate knowledge about the tool position using forward kinematics after accessing the angular locations of limbs. This paper presents a simulation study in which an encoder attached to the limbs gathers information about the angular positions. The measured angles are applied to the Kalman Filter (KF) and its variants for state estimation. This work focuses on the use of fractional order controllers with a Two Degree of Freedom Serial Flexible Links (2DSFL) and Two Degree of Freedom Serial Flexible Joint (2DSFJ) and undertakes simulations with noise and a square wave as input. The fractional order controllers fit better with the system properties than integer order controllers. The KF and its variants use an unknown and assumed process and measurement noise matrices to predict the actual data. An optimisation problem is proposed to achieve reasonable estimations with the updated covariance matrices.

Serial-robot Wrist-singularity Mitigation Along Alternative Optimally Adjusted Paths

Adjusting the displacement path of a serial robot encountering the wrist singularity to pass either through the singularity or around it mitigates its adverse effects. Both such path adjustments are commonly called singularity avoidance and are applied here to either a spherical or an offset wrist. These adjustments avoid high joint rates that can occur at singularity encounter. A recent through-the singularity method limits joint rates and accelerations in the robot with either a spherical or offset wrist when conducting a constant rate of traversal of the tool manipulated by the robot. A kinematic model adding multiple virtual joints allows a modified high-order path-following algorithm to maintain accurate tool position while achieving an optimal level of tool deviation in orientation. Whereas a path reversal resulting from a turning-point type singularity had been revealed for an offset wrist over a finite range of close-approach, these conditions are met when connecting the isolated path segments. Procedures are developed here with this capability for an around-the-singularity path. Choosing between the through and around-singularity alternatives offers the overall optimum.

FPLP3D: Security robot for face recognition in the workplace environment using face pose detection assisted controlled FACE++ tool position: A three-dimensional robot

BACKGROUND: In recent years, several tracker systems have been developed to monitor a 3-dimensional skull position for facial action whereas, various tracker systems simultaneously analyze the single sequence of video, which can be provided with low-quality cameras and less security. Initially, implementing a 2-D face detector and an unrepentance system has been suggested; furthermore, it has been improved using an integrated 3-D face initialized scheme for the real-time tracker in the present face recognition systems. OBJECTIVES: To overcome the present setbacks of the conventional systems, Face Pose Detection assisted controlled FACE++ tool position of Three-Dimensional Robot (FPLF3D) has been proposed in this article. Furthermore, the suggested proposed configuration has a high-end monitoring approach, which is used to improve the reliability of the robot’s human-machine contact in the workplace environment for security assistance. Additionally, the robot’s direction can be controlled by the operator’s head position assessment of the camera (or any active viewing system) using a three-dimensional robot. RESULTS: Besides, the applications that are imitated by headers like telepresence, computer-generated reality, and video competitions will directly take advantage of the strategies introduced in this paper. CONCLUSION: Finally, real video tests at the lab-scale level show the accuracy and usefulness of the approaches proposed in this research outperform the existing methods used for tracking.

A new approach to find gouge free tool positions for a toroidal cutter for Bezier surfaces in Five axis machining

We implement and test a multi-point machining tool positioning technique that positions the tool using only a variation on gouge checking. The result is a method that is roughly twice as fast as an earlier method that performed a numerical search to find a tool position with multiple points of contact with the design surface. A GPU implementation provides an additional factor of ten speedup. Verification of the method was done via simulation and machining and measuring physical parts.