Evaluation and Reduction of Measurement Uncertainty of a Double-Ballbar with Extended Measuring Range
 
More details
Hide details
1
Institute of Mechatronic Engineering, Chair of Machine Tools Development and Adaptive Controls, Dresden University of Technology, Germany
 
2
Fraunhofer Institute for Machine Tools and Forming Technology, Fraunhofer IWU, Germany
 
 
Submission date: 2026-02-06
 
 
Acceptance date: 2026-04-22
 
 
Online publication date: 2026-05-20
 
 
Corresponding author
Christoph Peukert   

Institute of Mechatronic Engineering, Chair of Machine Tools Development and Adaptive Controls, Dresden University of Technology, Germany
 
 
 
KEYWORDS
TOPICS
ABSTRACT
The double-ballbar (DBB) is a cost-effective, easy-to-automate, and fast measurement device for the kinematic calibration of machine tools and robotic systems. To extend its bandwidth of applications, a DBB with a larger measuring range has been developed. This device has now been comprehensively examined for the first time with regard to its systematic and stochastic measurement uncertainty. This paper focuses on the DBB’s static behaviour – i. e. deformation due to its own weight – and on thermally induced length measurement deviations, arising from environmental conditions and self-heating due to electrical power losses. For the evaluation of a DBB with 150 mm stroke, an Abbe-compliant reference measurement arrangement with a laser interferometer was implemented in an air-conditioned measuring room. Based on the results, an approach for correcting the systematic temperature-dependent length measurement deviation was implemented and validated. The DBB can thus achieve a measurement uncertainty significantly below 10 µm over a 150 mm stroke under known environmental conditions. This enables its application in the kinematic calibration of machine tools.
REFERENCES (30)
1.
KAUSCHINGER B., FRIEDRICH C., ZHOU R. IHLENFELDT S., 2020, Fast Evaluation of the Volumetric Motion Accuracy of Multi-Axis Machine Tools Using a Double-Ballbar, Journal of Machine Engineering, 20/3, 44–62, Wroclaw Board of Scientific Technical Societies Federation NOT.
 
2.
N.N., ISO 230-4: Test Code for Machine Tools - Part 4: Circular Tests for Numerically Controlled Machine Tools, International Organization for Standardization, 02/2022.
 
3.
MARWITZ J. A., THEISSEN N. A., GONZALEZ BASSANTE M.K., FRIEDRICH C., HELLMICH A., ARCHENTI A., IHLENFELDT S., 2022, Accuracy Assessment of Articulated Industrial Robots Using the Extended- and the Loaded-Double-Ball-Bar, Journal of Machine Engineering, Wroclaw Board of Scientific Technical Societies Federation NOT.
 
4.
MERX M., 2025, Identifikation Kinematischer Parameter Anhand von Messungen Mit Einem Double-Ball-Bar-Messgerät Mit Erweitertem Messbereich, diploma thesis, HTW University of Applied Sciences Dresden.
 
5.
BRYAN J.B., 1982, A Simple Method for Testing Measuring Machines and Machine Tools – Part 1: Principles and Applications, Precision Engineering, 4/2, 61–69, Elsevier BV.
 
6.
BRYAN J.B., 1982, A Simple Method for Testing Measuring Machines and Machine Tools - Part 2: Construction Details, Precision Engineering, 4/3, 125–138, Elsevier BV.
 
7.
BRYAN J.B., 1982, Telescoping Magnetic Ball Bar Test Gage, US Patent No. 4435905, granted 13th March 1984.
 
8.
N.N., 2024, QC20 Ballbar, brochure of Renishaw plc, part no. L-8014-9054-01-A.
 
9.
N.N., 2010, QC20-W Kabelloser Kreisformtest, Brochure of Renishaw plc, part no. L-8014-9006.
 
10.
N.N., 2023, Advancing Robotic Automation – Faster, Easier and More Accurate Commissioning and Verification of Robots, brochure of Renishaw plc, part no. H-6827-8005.
 
11.
N.N., 2025, Rcs T-Serie - Benutzerhandbuch, user guide of Renishaw plc, part no. H-6828-8002-03-A.
 
12.
N.N., 2019, Etalon X-AX LASERBAR, website of Hexagon AB, https://hexagon.com/products/e....
 
13.
N.N., 2019, Etalon X-AX LASERBAR, Brochure of Hexagon AB.
 
14.
HÄRTIG F., KECK C., KNIEL K., SCHWENKE H., WÄLDELE F., WENDT K., 2004, Selbstnachführendes Laserinterferometer für die Koordinatenmesstechnik, Technisches Messen, 71, 227–232.
 
15.
KAUSCHINGER B., 2006, Verbesserung der Bewegungsgenauigkeit an einem Hexapod einfacher Bauart, Phd thesis, TU-Dresden.
 
16.
SZATMARI S., 2007, Kinematic Calibration of Parallel Kinematic Machines on the Example of the Hexapod of Simple Design, Phd thesis, TU-Dresden.
 
17.
GROßMANN K., KAUSCHINGER B., SZATMARI S., 2008, Kinematic Calibration of a Hexapod of Simple Design, Production Engineering, 2/3, 317–325, Springer Science and Business Media LLC.
 
18.
GROßMANN K., KAUSCHINGER B., 2008, Räumliche Referenzierung an Werkzeugmaschinen Mit Dem Double-Ball-Bar, ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb, 103/3.
 
19.
ZHOU R., KAUSCHINGER B., IHLENFELDT S., 2020, Path Generation and Optimization for DBB Measurement with Continuous Data Capture, Measurement, 155, 107550, Elsevier BV.
 
20.
ZHOU R., KAUSCHINGER B., FRIEDRICH C., IHLENFELDT S., 2020, Fast Evaluation of Volumetric Motion Accuracy of Multi-Axis Kinematics Using a Double Ballbar, Proceedings of the 10th Congress of the German Academic Association for Production Technology (WGP), Dresden, 23–24 September 2020, Lecture Notes in Production Engineering, Springer Berlin Heidelberg, 345–353, https://doi.org/10.1007/978-3-....
 
21.
ZHOU R., KAUSCHINGER B., IHLENFELDT S., 2021, Data Synchronization By Continuous Spatial Measurement with Double Ballbar, Measurement, 174, 108909, Elsevier BV.
 
22.
IHLENFELDT S., DROSSEL W.-G., KAUSCH M., FRIEDRICH C., WIESE T., JANKOWSKY L., 2022, Seamhex – Fast 6D Additive Manufacturing Using an Innovative Screw Extruder Applied on a Hexapod Parallel Kinematic, Special Issue: 5th International MERGE Technologies Conference (IMTC), 1st - 2nd December 2021, 5/1, Chemnitz University of Technology.
 
23.
N.N., 2025, Profilschienenführungen, Catalogue of HIWIN GmbH. Document no. GW-12-1-DE-2501-K.
 
24.
N.N., 2020, Ni36/Invar 36, datasheet of thyssenkrupp Materials Switzerland, https://d2zo35mdb530wx.cloudfr....
 
25.
N.N., 2017, LIK 41 Optical Linear Encoder with Online Compensation, Product brochure of Numerik Jena GmbH, https://www.numerikjena.com/fi....
 
26.
N.N., 2014, Measurement Data Monitoring System Testo Saveris, catalogue of Testo SE & Co. KGaA. Document no. 0981 8114/msp/I/11, 2014.
 
27.
CHAPMAN M.A.V., 2017, Environmental Compensation of Linear Laser Interferometer Readings, Renishaw plc. Technical white paper: TE329, Part no. H-5650-2050-03-A.
 
28.
N.N., 2011, Effect of Environmental Compensation Errors on Measurement Accuracy, Documentation of Renishaw plc. Part no. H-9908-0474-01-A, https://www.renishaw.com/resou...= AfmBOoptWTUPal_7rtF5KXYc6bMsArgQLjrz6jNQv-xDxE8wd9y7KiP1.
 
29.
N.N., 2023, Rcs L-Serie - Benutzerhandbuch, user guide of Renishaw plc, part no. H-6827-8016-01-A.
 
30.
N.N., 2026, ETALON X-AX LASERBAR, https://nexus.hexagon.com/home....
 
eISSN:2391-8071
ISSN:1895-7595
Journals System - logo
Scroll to top