Accuracy Improvement of a Laser Diode-Based System for Measuring the Geometric Errors of Machine Tools

Active methods are proposed to improve the measurement accuracy of a compact laser diode-based (LD-based) system, which is designed to measure the geometric errors of machine tools. The LD has some advantages, such as a small size, low cost and high efficiency. However, the laser spot of the LD is elliptical and the stability in the output power of the LD is low, which limits the accuracy of the measurement system, where the LD is used as the laser source. An active shaping method is proposed to shape the elliptical laser spot of the LD without adding additional optical elements. In addition, the laser beam drifts, including the linear drift and angular drift, are compensated in real-time by a proposed improved active error compensator, which consists of two drift feedback units and a Backpropagation Neural Networks-based PID controller, during the long-distance measurement. A series of experiments were conducted to verify the effectiveness of the proposed methods and the capability of the constructed LD-based system.