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

doi:10.3901/JME.260456

Abstract

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

CLC Number:

TH161

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.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260456

http://www.cjmenet.com.cn/EN/Y2026/V62/I14/49

References

[1] Li Z，ZENG Z，YANG Y，et al. Research progress in machining technology of aerospace thin-walled components[J]. Journal of Manufacturing Processes，2024，119：463-482.
[2] 王蕾. 基于细观的导轨表面接触性能有限元分析[D]. 天津：天津理工大学，2013. WANG Lei. Finite element analysis of contact performance for guideway surface based on microscopic [D]. Tianjin：Tianjin University of Technology，2013.
[3] WANG S，HE G，ZHANG D，et al. Innovative design methods for the geometric accuracy of machine tool guide rail oriented to spatial accuracy[J]. Journal of Manufacturing Processes，2024，119：483-498.
[4] 王子生，姜兴宇，刘伟军，等. 再制造机床装配过程误差传递模型与精度预测[J].计算机集成制造系统，2021，27(5)：1300-1308. WANG Zisheng，JIANG Xingyu，LIU Weijun，et al. Error propagation modeling and accuracy prediction for remanufactured machine tool assembly process [J]. Computer Integrated Manufacturing Systems，2021，27(5)：1300-1308.
[5] SHEN L，DING X，LI T，et al. Structural dynamic design optimization and experimental verification of a machine tool[J]. The International Journal of Advanced Manufacturing Technology，2019，104：3773-3786.
[6] BRETAS N G，PIERETI S A，BRETAS A S，et al. A geometrical view for multiple gross errors detection，identification，and correction in power system state estimation[J]. IEEE Transactions on Power Systems，2013，28(3)：2128-2135.
[7] LIU K，SONG L，HAN W，et al. Time-varying error prediction and compensation for movement axis of CNC machine tool based on digital twin[J]. IEEE Transactions on Industrial Informatics，2021，18(1)：109-118.
[8] BOSETTI P，BRUSCHI S. Enhancing positioning accuracy of CNC machine tools by means of direct measurement of deformation[J]. The International Journal of Advanced Manufacturing Technology，2012，58：651-662.
[9] NIU P，CHENG Q，CHEN C，et al. An approach for crucial geometric error analysis and accuracy enhancement of gantry milling machines based on generalized correlation sensitivity[J]. Journal of Manufacturing Processes，2024，119：401-413.
[10] 马蔷，李嵩松，丁宾，等. 数控车铣复合机床精度检验项目分析[J]. 金属加工(冷加工)，2023(4)：61-64，7. MA Qiang，LI Songsong，DING Bin，et al. Accuracy inspection items analysis for CNC turning-milling compound machine tools [J]. Metal Working (Cold Working)，2023(4)：61-64，7
[11] ZHANG Z，JIANG F，MING L，et al. Geometric error measuring，modeling，and compensation for CNC machine tools：A review[J]. Chinese Journal of Aeronautics，2024，37(2)：163-198，8.
[12] NIU P，CHENG Q，CHEN C，et al. An approach for crucial geometric error analysis and accuracy enhancement of gantry milling machines based on generalized correlation sensitivity[J]. Journal of Manufacturing Processes，2024，119：401-413.
[13] AJANI I，LU C. Assembly variation analysis of the non-rigid assembly with a deformation gradient model[J]. Assembly Automation，2022，42(1)：40-53.
[14] ZHONG X，LIU H，MAO X，et al. Influence and error transfer in assembly process of geometric errors of a translational axis on volumetric error in machine tools[J]. Measurement，2019，140：450-461.
[15] ZHI F，JI M，WONG P，et al. Modeling of CNC machine tool line rail assembly accuracy and its control method [J]. Insights of Automation in Manufacturing，2024，1(1)：118-126.
[16] GENG Z，TONG Z，JIANG X. Review of geometric error measurement and compensation techniques of ultra-precision machine tools[J]. Light：Advanced Manufacturing，2021，2(2)：211-227.
[17] HOLUB M，ROSENFELD J. Geometric Accuracy of Large Machine Tools[J]. Measurement in Machining and Tribology，2020，24(3)：56-62.
[18] LIU C，LAI J，LUO Y T. Design of a measurement system for six-degree-of-freedom geometric errors of a linear guide of a machine tool[J]. Sensors，2018，19(1)：5.
[19] ZHAO D，BI Y，KE Y. An efficient error compensation method for coordinated CNC five-axis machine tools[J]. International Journal of Machine Tools and Manufacture，2017，123：105-115.
[20] HSU Y，WANG S. A new compensation method for geometry errors of five-axis machine tools[J]. International Journal of Machine Tools and Manufacture，2007，47(2)：352-360.
[21] 殷建. 大型龙门式双摆头五轴数控机床误差补偿关键技术研究[D]. 上海：上海大学，2017. YIN Jian. Research on key technologies of error compensation for large gantry-type double pendulum head five-axis CNC machine tools [D]. Shanghai：Shanghai University，2017.
[22] 孙光明，杨景景，张大卫，等. 精密机床导轨装配误差一致性工艺控制方法研究[J]. 天津理工大学学报， 2024，40(4)：29-34. SUN Guangming，YANG Jingjing，ZHANG Dawei，et al. Research on consistency process control method for guideway assembly error of precision machine tools[J]. Journal of Tianjin University of Technology，2024，40(4)：29-34.
[23] 刘志峰，陈继民，李迎，等. 数控机床线轨装配精度建模及控制方法[J]. 吉林大学学报，2025，55(5)：1536-1543. LIU Zhifeng，CHEN Jimin，LI Ying，et al. Research on modeling and control method of linear guideway assembly accuracy for CNC machine Tools[J]. Journal of Jilin University，2025，55(5)：1536-1543.
[24] 李婷，缪东晶，李连福，等. 长导轨直线度分段测量拼接方法研究[J]. 计量学报，2022，43(7)：837-843. LI Ting，MIAO Dongjing，LI Lianfu，et al. Research on segmented measurement and splicing method for straightness of long guideway[J]. Acta Metrologica Sinica，2022，43(7)：837-843.
[25] 罗凯，陈培锋，王英. 基于光斑位置传感器的长导轨准直系统[J].激光技术，2018，42(1)：30-33. LUO Kai，CHEN Peifeng，WANG Ying. Collimation system for long guideway based on spot position sensor[J]. Laser Technology，2018，42(1)：30-33.