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Simplified Manufacturing of Machine Tools Utilising Mechatronic Solutions on the Example of the Experimental Machine MAX

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Reinventing Mechatronics

Abstract

This chapter presents a mechatronic system concept for highly productive and accurate machine tools. Using the example of an experimental machine called ‘MAX’, it will be demonstrated that the working precision of a machine can be increased whilst the effort required for machining and assembly of its mechanical components is kept to a minimum. Firstly, a novel machine structure is introduced, which allows a high reproducibility with low manufacturing effort and provides the necessary degrees of freedom for the correction of motion deviations as well as the additional actuators required for the compensation of dynamic excitations. The simplified requirements for production and assembly of the machine presented leads inevitably to large geometric and kinematic errors. These errors are modelled using rigid-body kinematics. Circularity tests and angular measurements are performed to verify the machine’s ability to correct its geometric-kinematic deviations. For a highly dynamic engraving process, the reduction of the dynamic excitation caused by the drive reaction forces is demonstrated using the principle of impulse compensation. Finally, an approach to the correction of elastic and thermo-elastic errors and the comprehensive modelling and simulation-based analysis of the experimental machine are outlined.

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Acknowledgements

The presented work was funded by the German Research Foundation (DFG) within the projects GR1458/48-3 “Basic investigations on the application of the pulse compensation for linear direct drives in a cross-slide”, GR1458/64-1 “Application potential of articulated coupled drive and guide elements for increase of movement dynamics and accuracy” and the subproject C06 in the Collaborative Research Centre SFB/Transregio 96 “Thermo-energetic Design of Machine Tools”. The authors gratefully thank the DFG for their generous support. Additional thanks go to Maria Kopp, Evi Karola Wörner, Maria Meier, Jessica Deutsch, Bertram Friedrich, Mingliang Yang, Ziyi Wang, Axel Fickert, Felix Bender, Ulysse Delplanque, Jiajun Ruan, Daniel Sandoval Ovalle, Xaver Thiem, Enrico Henschel, Sven Kung, Bin Zhou, Luca Di Giorgio, Simon Städtler and Holger Kretzschmar who supported us in developing the models, designing of components and performing experiments.

The chapter is dedicated to Prof. Dr.-Ing. habil. Knut Großmann, who developed the idea for the design concept.

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Authors and Affiliations

  1. Technische Universität Dresden, Dresden, Germany

    Steffen Ihlenfeldt, Jens Müller, Marcel Merx, Matthias Kraft & Christoph Peukert

Authors
  1. Steffen Ihlenfeldt
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  2. Jens Müller
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  3. Marcel Merx
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  4. Matthias Kraft
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  5. Christoph Peukert
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Corresponding author

Correspondence to Steffen Ihlenfeldt .

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Editors and Affiliations

  1. Design, Manufacture and Engineering Management, University of Strathclyde, Glasgow, UK

    Xiu-Tian Yan

  2. Dundee, UK

    David Bradley

  3. Malvern, PA, USA

    David Russell

  4. Department of Automation Engineering, School of Engineering Science, University of Skövde, Skövde, Sweden

    Philip Moore

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Ihlenfeldt, S., Müller, J., Merx, M., Kraft, M., Peukert, C. (2020). Simplified Manufacturing of Machine Tools Utilising Mechatronic Solutions on the Example of the Experimental Machine MAX. In: Yan, XT., Bradley, D., Russell, D., Moore, P. (eds) Reinventing Mechatronics. Springer, Cham. https://doi.org/10.1007/978-3-030-29131-0_10

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