Thạc Sĩ 3-Axis and 5-Axis Machining with Stewart Platform

i










Declaration

I hereby declare that this thesis is my original work and it has been written by me
in its entirety. I have duly acknowledged all
the sources of information which have been used in the thesis.

This thesis has also not been submitted for any degree in any university previously.




Ng Chee Chung
30 July 2012

Acknowledgements
ii

Acknowledgements

The author would like to express his sincere gratitude to Prof. Andrew Nee
Yeh Ching and Assoc. Prof. Ong Soh Khim for their assistance, inspiration and
guidance throughout the duration of this research project.

The author is also grateful to his fellow postgraduate students, Mr.
Vincensius Billy Saputra, Mr. Bernard Kee Buck Tong, Miss Wong Shek Yoon,
Mr. Stanley Thian Chen Hai and professional officer, Mr. Neo Ken Soon and Mr.
Tan Choon Huat for their constant encouragement and suggestions. Furthermore,
he is also grateful to Laboratory Technologist Mr. Lee Chiang Soon, Mr. Au Siew
Kong and Mr. Chua Choon Tye for their help in the fabrication of the components
and their advice in the design of the research project.

In addition, the author would like to acknowledge the assistance given by
the technical staff of the Advanced Manufacturing Laboratory, Mr. Wong Chian
Long, Mr. Simon Tan Suan Beng, Mr. Ho Yan Chee and Mr. Lim Soon Cheong.

Last but not least, the author would also like to acknowledge the financial
assistance received from National University of Singapore for the duration of the
project, and to thank all those who, directly or indirectly, have helped him in one
way or another. Table of Contents
iii

Table of contents
Declaration i
Acknowledgements . ii
Table of contents iii
Summary iv
List of Tables vi
List of Figures . vii
List of Symbols xiii
Chapter 1 Introduction 1
Chapter 2 Kinematics of Stewart Platform . 13
Chapter 3 Fundamentals of Machining . 39
Chapter 4 Three-Axis Machining 50
Chapter 5 Five-axis machining . 76
Chapter 6 Five-axis machining post-processor . 91
Chapter 7 Calibration of Stewart Platform 110
Chapter 8 Control interface . 124
Chapter 9 3-DOF modular micro Parallel Kinematic Manipulator for machining
. 130
Chapter 10 Conclusions and Recommendations . 160
References . 166
Appendices 172
Appendix A: NC Code tables 172
Appendix B: Coordinate of circular arc in NC program . 175
Appendix C: Sensors installation methods . 184
Appendix D: Image processing . 200
Appendix E: Interval time calculation 219 Summary
iv

Summary

There is an increasing trend of interest to implement the Parallel
Kinematics Platforms (Stewart Platforms) in the fields of machining and
manufacturing. This is due to the capability of the Stewart Platforms to perform
six degrees-of-freedom (DOF) motions within a very compact environment,
which cannot be achieved by traditional machining centers.

However, unlike CNC machining centers which axes of movements can be
controlled individually, the movement of a Stewart Platform requires a
simultaneous control of the six individual links to achieve the final position of the
platform. Therefore, the available commercial CNC applications for the
machining centers are not suitable for use to control a Stewart Platform. A
specially defined postprocessor has to be developed to achieve automatic
conversion of CNC codes, which have been generated from commercial CAM
packages based on the CAD models, to control and manipulate a Stewart Platform
to achieve the machining purposes. Furthermore, a sophisticated control interface
has been developed so that users can perform machining with a Stewart Platform
based on CNC codes.

Calibration of the accuracy of the developed NC postprocessor program
has been performed based on actual 3-axis and 5-axis machining processes
performed on the Stewart Platform. A machining frame with a spindle was
designed and developed, and a feedback system was implemented based on wire Summary
v

sensors mounted linearly along the actuators of the platform. Thus, the position
and orientation of the end-effector can be calibrated based on the feedback of the
links of the platform. Experimental data was collected during the machining
processes. The data was analyzed and improvement was made on the
configuration of the system.

Alternate machining processes are reviewed with Parallel Kinematic
Manipulators of different structural designs that have been used for the Stewart
Platform. The structural characteristics associated with parallel manipulators are
evaluated. A class of three DOF parallel manipulators is determined. Several types
of parallel manipulators with translational movement and orientation have been
identified. Based on the identification, a hybrid 3-.UPU (Universal Joint-
Prismatic-Universal Joint) parallel manipulator was fabricated and studied.


List of Tables
vi

List of Tables
Table 3.1 Characteristic of various structure concepts [Reimund, 2000] . 43
Table 3.2 Comparison of workspace of CNC machine and Stewart Platform 45
Table 4.1 Coordinate systems . 52
Table 9.1 Feasible limb configurations for spatial 3-DOF manipulators [Tsai,
2000] . 133
Table 9.2 Workspace of mobile platforms with various radii . 137
Table 9.3 Workspace of the base with various radii . 138
Table 9.4 Calibration Result of the Micro Stewart Platform with the CMM . 155
Table 9.5 Calibration Result of the Micro Stewart Platform with the CMM when
the Platform travels within boundary workspace 157
Table A1 Address characters [Ken, 2001] 172
Table A2 G-codes chart [Ken, 2001] 173
Table A3 Miscellaneous functions (M functions) [Ken, 2001] 174
Table D1 Difference of displacement value of each actuator corresponding to
100,000 counts of pulse of the stepper motor . 213
Table D2 Error of motion along the Z-axis . 215
Table D3 Coordinate of the calibrated Points . 217
Table E1 Previous data collected by manually moving the Stewart Platform 222
Table E2 The time calculation when the velocity is 50000 step/sec and the
acceleration is 500000 step/sec
2
222 List of Figures
vii

List of Figures
Figure 1.1 Serial kinematics chains [Irene and Gloria, 2000] 3
Figure 1.2 Parallel kinematics manipulator classifications . 5
Figure 1.3 The standard Stewart Platform [Craig, 1986] 7
Figure 1.4 Stewart Platform machining center . 9
Figure 2.1 The Gough-Stewart Platform . 14
Figure 2.2 Locations of the joints of the platform 16
Figure 2.3 Locations of the joints of the base . 16
Figure 2.4 The workspace of Stewart Platform when . 32
Figure 2.5 The algorithm of the workspace calculation 33
Figure 2.6 The singularity configuration of Stewart Platform [Yee, 1993] 37
Figure 3.1 Standard postprocessor sequences . 41
Figure 3.2 CNC model inputs/outputs schematic representation 42
Figure 3.3 Comparison of the workspace of Stewart Platform (blue color dots) and
CNC machine (red color lines) . 44
Figure 3.4(a) Dexterous workspace (red color box) of the Stewart Platform (Front)
. 46
Figure 3.4(b) Dexterous workspace (red color box) of the Stewart Platform (Side)
. 46
Figure 4.1 The coordinate system of a Stewart Platform 50
Figure 4.2 Comparison of the coordinate systems of the cutting tool and the
Stewart Platform 51
Figure 4.3 Cutting tool and platform movements during the machining process for
Stewart Platform 52
Figure 4.4 Format of an NC program . 56
Figure 4.5 Flow chart of identification algorithm to evaluate address characters
and the respective values . 58
Figure 4.6(a) Flow chart of algorithm to determine maximum number of G code59
Figure 4.6(b) Flow chart of algorithm to determine maximum number of M code
. 60
Figure 4.7 Flow chart of matrix preparation for the corresponding character
address of an NC program 62
Figure 4.8 Flow chart of algorithm to assign the value of character addresses of an
NC program to the respective character addresses matrix array . 63
Figure 4.9 Flow chart of algorithm to determine the characteristics of the
coordinate system 65
Figure 4.10 Flow chart of algorithm to determine the values of X-, Y- and Z-
coordinates 66
0 ,0 ,0   
  List of Figures
viii

Figure 4.11 Flow chart of algorithm to determine the cutting plane and the style of
the cutting path 68
Figure 4.12(a) Flow chart of algorithm to convert NC program to machine
trajectory . 69
Figure 4.12(b) Flow chart of algorithm to convert NC program to the machine
trajectory . 70
Figure 4.13 Trajectory path of a Stewart Platform translated from an NC program
. 71
Figure 4.14(a) The pocketing machining process: plot outline in MasterCam . 72
Figure 4.14(b) The pocketing process: MasterCam generate the tool cutting path
. 72
Figure 4.14(c) The pocketing process: Simulation of cutting path in MasterCam 73
Figure4.14(d) The pocketing process: Generate trajectory path . 73
through MATLAB
®
73
Figure 4.14(e) The pocketing process: Machine workpiece through the contouring
process . 74
Figure 4.15 3D cutting path generated from the NC program created from model
in MasterCam 75
Figure 4.16 Outcome of machining on a Stewart Platform 75
Figure 5.1 Geometric error associated with tolerance between freeform surface
and designed surface . 77
Figure 5.2 A constant step over distance in the parametric space does not
generally yield a constant step over in the Cartesian space [Liang, 2002] . 78
Figure 5.3 Triangular tessellated freeform surface . 79
Figure 5.4 Standard triangular representation of STL model . 80
Figure 5.5 Generation of CC points 83
Figure 5.6 Determination of the intersection points between the cutting plane and
the face on the freeform surface 85
Figure 5.7(a) Flow chart for the generation of CC points . 86
Figure 5.7(b) Flow chart for the generation of CC points 87
Figure 5.8 Local Coordinate System (LCS) Setup . 88
Figure 5.9 Collision between tool and freedom surface . 89
Figure 5.10 Gouging . 90
Figure 6.1 Comparison of (a) 5-axis machining center and (b) Stewart Platform 92
Figure 6.2 Various coordinate systems defined in the Stewart Platform 93
Figure 6.3 Orientation of mobile platform around Y-axis 95
Figure 6.4 Relationship between the cutting tool frame LCS and the workpiece
frame LCS . 97 List of Figures
ix

Figure 6.5 Normal Vector of Face intersected with the Cutting Plane . 99
Figure 6.6 ASCII STL text format 101
Figure 6.7 The surface model derived from the vertices and faces 101
Figure 6.8 Tessellated triangular surfaces of the freeform surface . 102
Figure 6.9 Intersected points with norm (green dot line) along the cutting plane
. 103
Figure 6.10 Intersected points of the freeform surface with one cutting plane and
perpendicular lines (green) are the normal of the intersected points 104
Figure 6.11 Generation of the intersected points with a series of cutting planes 105
Figure 6.12 Generation of the intersected points with a series of cutting planes 106
Figure 6.13 Trajectory path of the Stewart Platform generated based on the LCS
of the freeform surface 107
Figure 6.14 Trajectory path of the Stewart Platform with retracted points 107
Figure 6.15 Simulation of 5-axis machining in MATLAB
®
. 108
Figure 6.16 5-axis machining result 109
Figure 7.1 The mounting of the sensors to the sensor holder . 111
Figure 7.2 The model of the trajectory path of the end-effector based on the
feedback of the wire sensors while the platform was moving along the Z-axis . 112
Figure 7.3 The model of the trajectory path of the end-effector based on the
feedback of the wire sensors while the platform was moving along the Z-axis
(front view) 113
Figure 7.4 The model of the trajectory path of the end-effector based on the
feedback of the wire sensors while the platform was moving along the X-axis . 114
Figure 7.5 The model of the trajectory path of the end-effector based on the
feedback of the wire sensors while the platform was moving along the Y-axis . 115
Figure 7.6 Feedback of actuators stroke position while the platform is . 117
being manipulated. 117
Figure 7.7 The corresponding position and orientation of the platform end-effector
with respect to the strokes of the actuators . 118
Figure 7.8 The Stewart Platform position and orientation feedback interface . 119
Figure 7.9 The real time feedback interface of the wire sensor when the platform
is being manipulated . 120
Figure 7.10 The tool path generated from the real time position feedback 120
Figure 7.11 Calibration of workpiece . 121
Figure 7.12 Comparison of calibrated result of the plotted point (Blue) and the
ideal point (Red) and the coordinate of the plotted points on the calibration plate
. 122
Figure 8.1 Motion control interface 125
Figure 8.2 Motion control feedback 126 List of Figures
x

Figure 8.3 Wire sensor interface . 127
Figure 8.4 NC program Interface 128
Figure 8.5 OpenGL Interface 129
Figure 9.1(a)(b) 6-Legged Micro Stewart Platform and 3-Legged Micro Stewart
Platform (c) PSU Micro Stewart Platform 135
Figure 9.2 Comparison of Workspace of 3-legged (red) and 6-legged (blue)
Parallel Manipulator 136
Figure 9.3 Workspace VS radius of Mobile Platform . 137
Figure 9.4 Workspace vs Radius of Base . 138
Figure 9.5 The workspace comparison between Passive Joint angle of 20º and 45º
. 140
Figure 9.6 The M-235.5 DG Actuator and Hephaist Seiko Spherical Joint . 142
Designs of the Micro Parallel Manipulator . 142
Figure 9.7 Parallel Manipulator system fabricated using the same modular
components (Prismatic Actuator, Spherical Joints, Universal Joints and Variable
Links) 143
Figure 9.8 (a) Pure Translational Platform, (b) Pure Rotational Platform 146
Figure 9.9 Hybrid UPU Parallel Kinematic Manipulator . 147
Figure 9.10 Schematic Diagram of the Parallel Kinematics Platform (PKM) 148
Figure 9.11 Calculation of the actual stroke of the link 149
Figure 9.12 Denavit-Hartenberg Representation 150
Figure 9.13 The UPU Modified Stewart Platform with a passive prismatic middle
link 151
Figure 9.14 The Relationship between the Surface Point and the spherical joint152
Figure 9.15 Workspace of the Surface Point of the Hybrid PKM 153
Figure 9.16 Accuracy Calibration of the Micro Stewart Platform with CMM . 154
Figure 9.17 Displacement and Rotational Error Analysis 156
Figure 9.18 Integration of the hybrid 3-DOF PKM into 3-axis machining center
. 159
Figure 9.19 The machined workpiece . 159
Figure 10.1 The theodolites system based on the principle of triangulation 164
Figure B1 Generic circular arc motion of the machining point in one plane 176
Figure B2 Clockwise circular arc motion with angle of starting point θ smaller
than angle of ending point β with respect to reference point 178
Figure B3 Clockwise circular arc motion with angle of ending point smaller than
angle of starting point with referred to reference point . 178
Figure B4 Clockwise circular arc motion with starting point at the right side and
ending point at the left side of the reference point 179 List of Figures
xi

Figure B5 Clockwise circular arc motion with starting point at the left side and
ending point at the right side of the reference point 180
Figure B6 Clockwise circular arc motion with starting point and ending point at
the left side of the reference point with angle theta larger than angle beta . 181
Figure B7 Clockwise circular arc motion with starting point and ending point at
the left side of the reference point with angle theta smaller than angle beta 182
Figure C1 The developed Stewart Platform and the Epsilon wire sensor . 184
Figure C2 The MATLAB® simulation of the forward kinematics calibration
system 186
Figure C3 The laser pointer calibration system diagram 187
Figure C4 The MATLAB® simulation of the laser platform calibration system 189
Figure C5 The wire sensor calibration system diagram 191
Figure C6 Cartesian Coordinate of the vector points 193
Figure C7 The calibration setup for wire sensor . 195
Figure C8 Graph of Comparison between theoretical data and actual data from
Multimeter . 196
Figure C9 Graph of Actual Length vs Voltage of the wire sensor 197
Figure C10 Wire sensor interface . 198
. 198
Figure C11 The Sampled Wave Signal of the wire sensors 198
Figure D1 The original image with marked points . 200
Figure D2 Black and white image . 201
Figure D3 the Image is rotated into the position so that it is in line with the
horizontal level 202
Figure D4 Calibrated points of the image in terms of red color for the printed
point and blue color highlighted dots for the points marked by the pen . 202
Figure D5 the tilted line (in green) plotted with respected to the marked points in
the middle of the graph . 203
Figure D6a All three sets of coordinates of the Printed Points (Red), Marked
Points (Blue) and Modified Points (Green) 204
Figure D6b All three sets of coordinates without background image . 205
Figure D7 the errors of calibrated points along the X-axis . 206
Figure D8 the errors of calibrated points along the Y-axis . 207
Figure D9(a) the distance between two adjacent points along the X-axis 208
Figure D9(b) the distance between two adjacent points along the Y-axis 209
Figure D10 The unevenness of the points motion even though it is moving 210
in the X-direction 210 List of Figures
xii

Figure D11 The corresponding error resulting from the ratio of actuator movement
over the counter of 100,000 steps from the controller 212
Figure D12 The LVDT-like device . 214
Figure D13 Calibrated Workpiece 216
Figure D14 The comparison of coordinates between the actual calibrated points
and the theoretical points 218
Figure E1 Distance, Velocity and Acceleration Diagram . 220
Figure E2 Flow chart of the interval time control . 223 List of Symbols
xiii

List of Symbols

F e The effective DOF of the assembly or mechanism

The DOF of the space in which the mechanism operates

L Number of links

j Number of joints

f i Degree-of Freedom of i-th joint

I d Idle or passive Degrees-Of-Freedom

X p , Y p , Z P The Origin of Platform

X B , Y B , Z B The Origin of Base

P i Platform attachment joints, spherical joints, i = 1, 2 , 6

B i Base attachment joints, universal joints, i = 1, 2 , 6

σ i The magnitude of the links vector, , i = 1, 2 , 6

W The force that act on the platform

A The area of the platform, m
2

Υ The Poisson’s Ratio

I Inertia


Leg vector

R Rotational matrix

S Sine

C Cosine

V Matrix of Cartesian Velocities

W Matrix of Joint Velocities

D, d Euclidean distance between the two vectors

i
l
List of Symbols
xiv


NaN Not a Numerical number

Rot 3x3 3 x 3Rotation matrix of Stewart Platform

Tr 3x1 3 x 1Translational matrix of Stewart Platform

T Homogeneous Coordinate

Ξ Tolerance of Error

t

Translational Vector

i
X


Matrix of pose vector of Stewart Platform

G Mapping function of length of actuators to the pose of the
Stewart Platform

H Differentiation of Mapping function G with the corresponding
element of the pose vector of Stewart Platform

R xyz Rotation matrix around X-axis, Y-axis and Z-axis

Rz,α Rotation matrix around Z axis with rotational angle of α

Ry,β Rotation matrix around Y axis with rotational angle of β

Rz,γ Rotation matrix around Z axis with rotational angle of γ

A z Area of the workspace of Stewart Platform

V Volume of Workspace

f bi Force acting on the spherical joint of the mobile platform

f ai Force acting on the universal joint of the base of Stewart
Platform

ω p Angular velocity of the mobile platform

i
n i Moment acting on the actuator


m 1

Mass of cylinder of actuator

m 2 Mass of piston of actuator
List of Symbols
xv

e 1i Distance between the center of mass of the cylinder and the
bottom of the cylinder

e 2i Distance between the center of mass of the piston and the top of
the piston

v 1, v 2 Velocity of the center of mass of the cylinder and piston

B
n p Moment about the center of mass of the mobile platform


i
 Actuating force of the platform


X_platform,
Y_platform,
Z_platform
Coordinates of mobile platform in local coordinate system

X_CNC_Code,
Y_CNC_Code,
Z_CNC_Code
Coordinate of XYZ coordinates in NC program

X abs ,Y abs ,Z abs Absolute coordinate of X, Y and Z position of the mobile
platform

X rel ,Y rel ,Z rel Relative coordinate of X, Y and Z position of the mobile
platform

C Vector between cutter contact point and normal N of the
triangular faces of the freeform surface

N Vector of normal to the face of the triangle in the freeform
surface

α c Critical angle of Collision

α 1 , α 2 Critical angle of gouging

V mw Vector from milling cutter to workpiece

N R Magnitude of vector of the normal to the triangle face of the
freeform surface

Chapter 1 Introduction
1
Chapter 1 Introduction

Parallel manipulators can be found in many applications in the industry,
such as vehicle and airplane simulators [Stewart, 1965], adjustable articulated
trusses [Reinholtz and Gockhale, 1987], mining machines [Arai et al, 1991],
positioning devices [Gosselin and Hamel, 1994], fine positioning devices, and off-
shore drilling platforms. Recently, it has also been developed as high precision
milling machines, namely, a hexapod machining center by Giddings and Lewis in
1995. A Stewart Platform is a form of manipulator with six degrees of freedoms
(DOF), which allows one to provide a given position and orientation of the
surface in the vicinity of any point of the platform on its three Cartesian
coordinates and projection of the unit of normal vector [Alyushin, 2010].

The design of parallel manipulators can be dated back to 1962 when
Gough and Whitehall [Gough, 1962] devised a six-linear jacking system for use as
a universal tire testing machine. Stewart presented his platform manipulator for
use as an aircraft simulator in 1965 [Stewart, 1965]. Hunt made a systematic study
of the parallel manipulator structures [Hunt, 1983]. Since then, parallel
manipulators have been studied extensively by many other researchers [Tsai,
1996].

However, greater interests in the application of these mechanisms in the
metalworking field have only grown in the last decade. The first CNC-type
hexapod machine tool prototype (Variax from Giddings & Lewis and the Chapter 1 Introduction
2
Octahedral Hexapod from Ingersoll) was presented at the 1994 International
Machine Tool Show in Chicago. These prototypes were enthusiastically
welcomed as the new generation of machine tools due to their specific
characteristics [Irene and Gloria, 2000]:
 Higher payload to weight ratio
 Non-cumulative joint error
 Higher structural rigidity
 Modularity
 Location of the motors close to the fixed base
 Simpler solution of the ‘inverse’ kinematics problem

However, there are still many disadvantages of the Stewart Platform as
compared to the serial manipulators, such as a limited workspace and problems in
singularity configuration. Furthermore, it also has complicated forward kinematics
due to the closed loop configuration of the system.

Configuration and classification

Most of the robots being used in the industries today are serial robots or
serial manipulators. Manipulators are basically mechanical motion devices,
generally with two or more DOF. Serial manipulators are normally made up of
between two to six rigid links with prismatic and/or revolute joints connecting the
links in an open kinematics chain. Examples of this kind of robots include the
PUMA 560 series of robot arm and the SCARA type Adept One robot arm [Yee
1993].