大行程机床导轨装配精度控制:误差建模与分阶段迭代补偿

doi:10.3901/JME.260456

机械工程学报 ›› 2026, Vol. 62 ›› Issue (14): 49-58.doi: 10.3901/JME.260456

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大行程机床导轨装配精度控制:误差建模与分阶段迭代补偿

蔡畅根¹, 吴重军¹, 陈聪¹, 林志俭², 蒋能², 王庆霞¹

1. 东华大学机械工程学院上海 201620;
2. 阿帕斯数控机床制造(上海)有限公司上海 200131

收稿日期:2025-07-13 修回日期:2026-02-10 发布日期:2026-08-29
作者简介:蔡畅根，男，2001年出生，硕士研究生。主要研究方向为数控机床。E-mail：18879478030@163.com;吴重军(通信作者)，男，1988年出生，博士，副教授，博士研究生导师。主要研究方向为精密制造技术、高档数控装备。E-mail：wcjunm@dhu.edu.cn
基金资助:
上海市经信委促进产业高质量发展专项资助项目(CYLGG-2024-1-32)。

Assembly Accuracy Control of Long-Stroke Machine Tool Guideways: Error Modeling and Hierarchical Collaborative Compensation

CAI Changgen¹, WU Chongjun¹, CHEN Cong¹, LIN Zhijian², JIANG Neng², WANG Qingxia¹

1. School of Mechanical Engineering, Donghua University, Shanghai 201620;
2. APUS CNC Machine Tool Manufacturing (Shanghai) Co., Ltd., Shanghai 200131

Received:2025-07-13 Revised:2026-02-10 Published:2026-08-29

摘要/Abstract

摘要： 针对大行程机床导轨在自重变形与装配作用下装配精度退化的问题，建立了自重、装配与制造误差三因素直线度综合模型。各误差源统一等效为沿导轨方向的位移轮廓，采用最小二乘基准直线拟合去除刚体平移与整体倾斜分量，实现同一去基准评定规则下的线性合成。基于水平仪与自准直仪分段测量获取直线度数据，结合扭矩—预紧力换算与制造误差拟合完成参数标定并进行验证。与不含自重项的两因素模型相比，三因素模型在Z向与Y向的峰谷值(PV)一致性分别提高至0.880和0.893，Y向方均根误差(RMSE)由5.48 μm降至4.38 μm。进一步构造逆向补偿目标并采用分阶段迭代补偿，在扭矩与接触应力约束下实现导轨直线度误差抑制。同侧1号导轨Z向与Y向直线度分别降低65.2%和55.9%，2号导轨分别降低68.1%和66.0%，对侧3号与4号导轨直线度误差综合降幅分别为77.4%和60.0%。结果表明，自重变形是大行程导轨装配精度退化的重要来源，分阶段迭代补偿可在满足工程约束的前提下有效降低直线度误差并提升装配精度。

关键词: 大行程机床, 导轨装配精度, 自重变形, 装配变形, 制造误差, 分阶段迭代补偿

Abstract: An assembly-accuracy degradation problem of long-stroke machine tool guideways under the combined effects of self-weight deformation and assembly is addressed. A three-factor straightness synthesis model incorporating self-weight, assembly, and manufacturing errors is established. Each error source is equivalently represented as a displacement profile along the guideway direction, and rigid-body translation and overall tilt components are removed by least-squares reference-line fitting, so that linear synthesis is performed under a unified datum-removal evaluation rule. Straightness data are obtained by segmented measurements using a precision level and an autocollimator, and parameter identification and model validation are conducted by combining a torque-preload conversion with manufacturing-error fitting. Compared with a two-factor model without the self-weight term, the peak-to-valley (PV) consistency in the Z and Y directions is increased to 0.880 and 0.893, respectively, and the root-mean-square error (RMSE) in the Y direction is reduced from 5.48 μm to 4.38 μm. Furthermore, an inverse compensation target is constructed and a stage-wise iterative compensation strategy is adopted to suppress guideway straightness errors under torque and contact-stress constraints. The Z and Y direction straightness of guideway No. 1 on the same side is reduced by 65.2% and 55.9%, respectively, and that of guideway No. 2 is reduced by 68.1% and 66.0%, respectively; the overall reductions of straightness errors for guideways No. 3 and No. 4 on the opposite side are 77.4% and 60.0%, respectively. The results indicate that self-weight deformation is an important source of assembly-accuracy degradation for long-stroke guideways, and stage-wise iterative compensation effectively reduces straightness errors and improves assembly accuracy under engineering constraints.

Key words: large-stroke machine tools, guideway assembly accuracy, self-weight deformation, assembly-induced deformation, manufacturing error, stage-wise iterative compensation

中图分类号:

TH161

蔡畅根, 吴重军, 陈聪, 林志俭, 蒋能, 王庆霞. 大行程机床导轨装配精度控制:误差建模与分阶段迭代补偿[J]. 机械工程学报, 2026, 62(14): 49-58.

CAI Changgen, WU Chongjun, CHEN Cong, LIN Zhijian, JIANG Neng, WANG Qingxia. Assembly Accuracy Control of Long-Stroke Machine Tool Guideways: Error Modeling and Hierarchical Collaborative Compensation[J]. Journal of Mechanical Engineering, 2026, 62(14): 49-58.

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大行程机床导轨装配精度控制:误差建模与分阶段迭代补偿

Assembly Accuracy Control of Long-Stroke Machine Tool Guideways: Error Modeling and Hierarchical Collaborative Compensation

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