A new direct deformation sensor for active compensation of positioning errors in large milling machines

The positioning accuracy of large boring and milling machines (with axes travel larger than 5 m) is severely affected by structural deformations. Heat induced deformations, long-period deformation of foundations, and the machining process itself, cause time-dependent structural deformations of the machine body, which are difficult to model and to predict. In order to overcome these difficulties and to enhance the positioning accuracy, a composite sensor has been designed and tested, which allows direct and continuous (up to 250 Hz) measurement of geometrical deformations on machine structural elements. The present paper i) presents the operating principles of the proposed composite sensor, which is based on an array of Fiber-optics Bragg Gratings (FBG), ii) discusses requisites and performances of the sensor as well as the algorithm used to calculate the deformed shape as a function of the sensor output, iii) illustrates the results of a finite elements virtual model aimed to demonstrate the feasibility and to evaluate the expected performance of the sensor, and iv) validates the model by showing the results obtained by a sensor prototype giving a real-time measurement of the deformed shape of a structural beam.