Method and apparatus for characterizing and enhancing the functional performance of machine tools

A system for assessing a capability of a machine tool having a first axis slide having a first motion axis and a motion controller for interpreting program instructions to direct a movement of the first axis slide along the first motion axis, comprising:

• a data-processor-readable medium;
• data-processor-readable instructions for assessing a capability of a machine tool, the data-processor-readable instructions being stored on the data-processor-readable medium and comprising a definition of a measurable merit of machine tool performance and a definition of a first pattern of dynamic excitation commands representative of a first intended motion and definition of a second pattern of dynamic excitation commands representative of a second pattern of motion;
• a reference block;
• a sensor system for measuring a relative motion between the sensor system and the reference block;
• a data processor system comprising subsystems for:
• reading the data-processor-readable instructions on the data-processor-readable medium;
• electronically instructing the machine tool to drive the first axis slide along the first motion axis using the first pattern of dynamic excitation commands and to drive the first axis slide along the first motion axis using the second pattern of dynamic excitation commands;
• deriving from the sensor system a first quantification of the measurable merit corresponding to the first pattern of dynamic excitation commands;
• deriving from the sensor system a second quantification of the measurable merit corresponding to the second pattern of dynamic excitation commands;
• and
• encoding a map of machine tool performance in the data-processor-readable medium, the map identifying the first quantification of the measurable merit of machine tool performance as a function of the first pattern of dynamic excitation commands and the map identifying the second quantification of the measurable merit of the machine tool performance as a function of the second pattern of dynamic excitation commands.

A system for improving the performance of a machine tool comprising:

• an encoded map of machine tool performance stored in a data-processor-readable medium and identifying a plurality of quantifications of at least one measurable merit of machine tool performance, with each quantification of measurable merit being represented as a function of a plurality of patterns of dynamic excitation commands;
• an input device for accepting a machining job objective expressed as a function of at least a portion of the at least one measurable merit of machine tool performance;
• and
• a data processor system comprising subsystems for:
• receiving the machining job objective, reading at least a portion of the encoded map of machine tool performance,
• selecting an optimized pattern of dynamic excitation commands based at least in part upon the encoded map and the machining job objective, and
• providing the optimized pattern of dynamic excitation commands to a machine controller in the machine.