This master's thesis deals with the structural design of a universal test bench intended for the testing, diagnostics, and calibration of linear optical position encoders under controlled temperature changes, with a primary focus on Heidenhain products.
The theoretical part analyzes the current state of direct position measurement technologies, the physical principles of photoelectric scanning, and the factors affecting measurement accuracy, in particular the thermomechanical behavior of materials and the Abbe error. Within the system analysis, a multi-criteria analysis of materials was performed, based on which polymer concrete was selected for the supporting frame, combining a high decrement of vibration damping, thermal inertia, and the possibility of integrating functional elements directly into the casting.
The structural design includes a polymer concrete bed with a travel of 1500 mm with integrated internal water cooling and a distributed network of Pt100 temperature sensors, aerostatic linear guideways, an ironless linear motor, and a modular system of external insulation. To eliminate vibration transmission, the entire bed is mounted on active air springs with electronic tilting moment compensation. Accuracy validation is ensured by a Renishaw XL-80 laser interferometer and a Heidenhain PWM 21 diagnostic device.
The conclusion of the thesis contains a measurement methodology based on ISO 230 standards, a technical and economic evaluation with an estimate of total costs, and a summary of the test bench's benefits for research, educational, and service activities.