Angular error measurement of workpiece repositioning using a full-scale rotation detection method

Workpiece repositioning error has always been a key factor affecting manufacturing accuracy. The issues become more sensitive when machining microstructures with special morphologies, where the declination error caused by the repositioning may lead to microstructural defects. To solve this practical problem, in this paper, we report the design of a fixture that can detect the plane angular displacement error between the workpiece and the tool, namely the Rotation Correction Fixture (RCF). The fiducial marker referred to as polar microstructure is proposed and placed on the RCF edge. Angular displacement measurement is realized by observing the microstructural changes. Simultaneously, a Full-scale Rotation Detection (FRD) method is proposed to obtain the full-scale and high-precision angular displacement, including coarse extraction based on Fourier transform and fine extraction based on the Fast and Robust Feature-based Positioning method. Template matching is employed to eliminate the phase ambiguity in the Fourier transform. The results show that the proposed method can realize the calibration of the workpiece declination with a standard deviation error of 250.24 seconds, which meets the needs of workpiece precision positioning well.