White Paper: Manufacturing & Prototyping
How to Improve Machine Performance with Multi-Axis Motion System Error Budgeting
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This paper will explain how multi-axis motion systems can be analyzed to estimate functional point (work point) errors. Specifics on how to review system geometry and how to convert component-level errors into system-level errors will be discussed. A recommended calculation method, as well as ways to improve system performance, will also be examined.
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Overview
The white paper by John Lindell focuses on the analysis and budgeting of errors in multi-axis motion systems, which are critical in modern manufacturing processes that demand high precision. As part geometries become more complex and tolerances shrink, understanding and managing motion errors is essential for producing high-quality products, such as semiconductor chips and medical devices.
The paper outlines the various sources of motion errors, which can be categorized into linear and rotational errors across multiple axes. Each moving axis introduces potential errors that contribute to the overall functional point error of a machine. The author emphasizes the importance of establishing a coordinate reference frame to systematically analyze these errors and create an error budget.
Key applications are discussed, illustrating how specific motion errors can impact performance. For instance, in silicon wafer dicing, horizontal straightness errors can lead to cutting inaccuracies, while in optics inspection, vertical straightness and pitch errors can increase measurement uncertainty. The paper also highlights the role of feedback devices, such as laser interferometers and encoders, which are necessary for measuring the position of moving axes but also introduce their own inherent errors.
To improve system performance, the author suggests using a structured approach to error budgeting, which includes estimating total errors and exploring “what-if” scenarios to identify potential improvements. The paper also mentions the use of advanced modeling techniques, such as homogeneous transformation matrices, to accurately represent error values across the working volume of the motion system.
In conclusion, the white paper serves as a guide for machine designers and engineers, providing insights into the significance of motion error analysis and offering methods to enhance the accuracy and reliability of multi-axis motion systems in manufacturing.