Application Research of Visualization Technology in Error Analysis of Machine Tool Spindle

The spindle of a machine tool functions like a human arm and is one of the most critical components in the system. Its performance directly influences the overall accuracy and quality of the machine. As a result, spindle error testing has become an essential part of machine performance evaluation, fault analysis, and factory quality control. The testing typically involves several key aspects such as radial and axial runout measurement, thermal deformation analysis, and static stiffness assessment. This paper explores the application of visualization technology using the VTK development platform to enhance the analysis of spindle errors. By integrating 3D modeling of the machine and visualizing the spindle's error distribution, users can gain a more comprehensive understanding of how these errors affect the machine’s performance. This approach offers a much clearer insight compared to traditional text-based reports or 2D graphs, making it highly valuable for improving machine design and optimizing structural performance. **Spindle Error Test System** The spindle error test system was developed by the Shenyang Machine Tool (Group) Design and Research Institute. It consists of both hardware and software components. The software is primarily responsible for setting parameters, configuring channels, and displaying and saving real-time data. The underlying development is done in C++, while the user interface is built using C#. This ensures a fast and responsive system with an intuitive interface. Figure 1 shows the main interface of the software, where most operations—such as adjusting channel colors, setting sampling time, choosing data processing modes, defining display ranges, and controlling the laser displacement sensor—can be performed without switching windows. This significantly improves efficiency during testing.

Figure 1: Data Acquisition Main Interface

Figure 2 displays the configuration interface, where users can set up hardware parameters and channel settings. All configurations are saved in an XML file and automatically loaded when the software starts, ensuring consistency and ease of use.

Figure 2: Data Acquisition Configuration Interface

The hardware includes two IF2004 data acquisition cards from Mi Fu Company, each with four channels; five laser triangular reflection-type displacement sensors with a measuring range of 24–26 mm; five controllers; one 24V power supply module; cables; and an industrial computer. Figure 3 shows the schematic of a single-channel hardware setup.

Figure 3: One Channel Hardware Connection Diagram

With this configuration, the system can perform simultaneous 5-channel data acquisition at a frequency of 10 kHz per channel. Typically, one spindle axis is measured along with two other directions, allowing for the simultaneous measurement of X, Y, and Z axes. The displacement data can also be used to calculate the radial inclination angle of the spindle through data processing. The specific installation method of the laser displacement sensors is illustrated in Figure 4.

Figure 4: Schematic of Spindle Error Measuring Device Installation
1. Spindle check rod 2. Laser displacement sensor 3. Bracket

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