Development and calibration of self-centring probes for assessing geometrical errors of machines

A new type of probe for calibration, verification or interim checking of machine tools as well as robots or parallel-kinematics machine tools is presented in this paper. This probe is part of a ball-artefact-based method to assess the geometrical errors of linear and angular axes in a quick and reliable way. The discussion about the best design concept for the self-centring probe, the mathematical modelling and design process of one of those concepts and the development of three different prototypes are shown. Different sensors and design options were developed to optimize the size and cost of the probe. The calibration of the probe prototypes by way of a kinematically coupled reference device to allow on-machine tests is shown. The uncertainties obtained were around 1 mu m for one of the prototypes and below 5 mu m for the other two. Finally, results of a geometrical verification of a machine tool are demonstrated, with values similar to the ones achieved using other methods, such as laser interferometry. Compared to those other methods, the new technique was shown to be less time consuming.