Institute of Production Engineering and Laser Technology
Future technologies and new machine tool research activities Univ. Prof. DI. Dr. F. Bleicher
Institute of Production Engineering and Laser Technology Vienna University of Technology
16. Sept. 2010
Page 1
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Main topics at the IFT Institute of Production Engineering and Laser Technology Head: Univ. Prof. Dr. F. Bleicher
Industrial Metrology Univ. Prof. Dr. N. Durakbasa Quality Management Production Metrology Nano-Metrology GPS - Geometrical Product Specification
Laboratory for Precision Measuring Univ. Prof. Dr. N. Durakbasa
Area of Research Cutting Technology
Area of Research Laser- und Forming Technology
Univ.Prof.Dr. F. Bleicher
N.N.
Computer Integrated Manufacturing
Production Engineering
Univ. Prof. Dr. B. Kittl
Univ. Prof. Dr. F. Bleicher
NC-Controls Mechatronics Production Control MES ERP
Production Automation Process Technology Cutting Technologies Machine tool Industrial robotics
Laboratory of Production Engineering DI Bernreiter
Intelligent Manufacturing Systems Univ.Prof. Dr. B. Katalinic Production System Analysis and Design Layout Planning Facility Concepts Robotics Technology - Innovation
Laboratory of Machining Technology Dr. R. Mertz
Institute of Production Engineering and Laser Technology Vienna University of Technology
Laser and Forming Technology Univ.Prof. Dr. G. Liedl Laser Manufacturing Laser supported Forming Laser development Laser optic development
Laboratory for Laser and Forming Technology Univ. Prof. Dr. G. Liedl
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Research work at the IFT Production Engineering Univ. Prof.Dr. F. Bleicher
Production Automation
Technology
Machine control concepts Optimisation of control systems NC programming and simulation, CAM Software technology for mechanical engineering Flexible automation Machinery system integration Robotics in building constructoion Production metrology Research of static, dynamic and thermal behaviour of machine tools
Cutting technologies with geometrically defined and undefined cutting edges Forming technologies Assembly methods Basic research in processes Process analysis and optimisation Analysis of tool wear Application of cooling lubricants Dry machining Metrological process analysis and assessment
Machine Tool Development of standard and new machine tools concepts Design, calculation and simulation of machine tools (CAD-FEM) Metrological analysis and assessment of machine tool behaviour Optimisation of mechanical components by use of: Simulation (FEM) Static and dynamic analysis Energy efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
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model based description and simulation
main topics
Optimization and enhancements of industrial applications
Research and experimental development experimental development
technology and processes
production systems and control technology
IT-based production management and quality assurance
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 5
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 6
Hybrid machining – US-assisted machining
Machining of brittle hard or difficult to machine materials Piezo element driven vibrating systems Single axis system: amplitude max. 11µm at 13,44 kHz up to 21kHz Dual axes system: amplitude max. 20µm at up to 500 Hz
Single axis system
Dual axes system Institute of Production Engineering and Laser Technology Vienna University of Technology
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Machining brittle hard materials - fly wheel test entry zone
B1
Institute of Production Engineering and Laser Technology Vienna University of Technology
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High performance deep-hole drilling PCD - Position controlled drilling PFA - Pulsative feeding actuator
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Electrochemical milling
gap distance in [µm]
Process precision defined by width of electric pulse
pulse width in [µm]
Source:
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Flexible automation
Railwayindustry
Vehicle Industry
Flexible Automation
Robotics
Robot Aided Reconfiguration
RAR
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 11
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 12
Machine tool concepts – since 2000 transfer machining center
double spindle machining center
transfer line
300.000
flexible transfer line flexible manufacturing system machining center
flexible manufacturing cell NC-machine required space energy consumption total cost of ownership overall lifecycle costs
pr ec is i re on lia bi ef lity fic ie nc y
productivity [parts/year]
costs
flexibility
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Transfer machining center Inline transfer technology
Inverse machining technology
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Design of new machine tool concepts Parallel kinematics: X-CUT Quickstep (Tripod)
Robot machining Exechon Tricept
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 15
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 16
Coupled simulation – mechanics/control Calculation of static and dynamic system features Substituted mechanical system
Mechanical structure transferred to Matlab/Simulink©
right lower slide
right upper slide
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Exhausting system - simulation of MQL Air flow speed distribution in the XY plane
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 18
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Energy profile – energy efficient machine tools pneumatic
axis
machine process
automation
material - work piece - tool cutting edge geometry
tool changer
infeed
spindle - vibration - torque - rotational speed
…
…
feed rate
spindle
hydraulic
axis: - current - friction - circularity - parallel feed
periphery pneumatic - pressure - air consumption - operating cycle hydraulic - fill level - temperature automation chip conveyor • ...
chip conveyor
…
…
Regulations available or in preparation: ISO 14001, ISO 16001 Environmental management system ISO 14062 Life cycle assesment ISO 14955 Environmental evaluation of machine tools Institute of Production Engineering and Laser Technology Vienna University of Technology
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Energy profile - machine tools
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Determination of energy profile Machining (motion and conrol) Process cooling /conditioning
Experimental setup on the machine tool VF 3 Haas 3,5%
11,3%
3,7%
50
Tool and part handling
1 58,2%
23,3%
current [A]
40
Machine cooling/heating Waste handling and transportation
ISO TC 39/WG 12
30
S … Apparent power [W] 20
4
3
P … Effective power [W]
2 10
Q … Idle power [W] 20
50
100
150 200 time [s]
250
300
1 spindle ramp-up 2 4 contact width: ae= 2mm, 4mm 3 fast feed motion
η … Efficiency … Volume flow [l/min] – compressed air … Volume flow [l/min] - lubrication
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 22
Outline
1
Profile of the IFT
2
New technologies
3
Innovative machine tool concepts
4
Model based system design
5
Eco-design of machine tools
6
Overall efficiency
Institute of Production Engineering and Laser Technology Vienna University of Technology
Page 23
Integrated diagnostics system trend analysis
ball bar test
axis monitoring
diagnostics predictive universal axis test
axis synchron test condition based
Improved maintenance strategy and new business models
predetermined
after breakdown Institute of Production Engineering and Laser Technology Vienna University of Technology
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Integrated monitoring system 300
recording
Aufzeichnung
Drehmoment [Nm]
250
Belastungsprofile load profile
Max. Drehmoment Mittl. Drehmoment
200
150
100
50
TCO‐ Datenbank database
0
60
Garantie‐ guarantee vereinbarung
50
40
Energie [kWh]
agreement
life cycle TCO‐Daten data
Energieverbrauch energy
consumption
30
20
10
0
Berichts‐ reporting wesen
Sonstiges
Ausfallkosten
Leitungen rgungseinheit
breakdown costs
eugwechseler Rundachse Linearachse Hauptspindel
energy consuption diagnostics / analysis of load collectives preventive maintenance overall life cycle costs Institute of Production Engineering and Laser Technology Vienna University of Technology
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Overall process monitoring and optimization daily energy consumption
ERP level ePSatellite
client
days
feature based energy consumption SAP
feature 4
feature 2
Q-DAS feature 1
feature 3
feature 5
hours
value and non value added energy consumption non value added
MES level machine
Machine level
machine
non value added value added
seconds ePS-client IMD control data machine
process energy consumption
user data
drive
m-seconds
Institute of Production Engineering and Laser Technology Vienna University of Technology
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Contact
Institute of Production Engineering and Laser Technology Karlsplatz 13 1040 Wien Austria Tel.: +43-(0)1-58801-31101 Fax: +43-(0)1-58801-31199 E-Mail:
[email protected] Homepage: http://www.ift.at Institute of Production Engineering and Laser Technology Vienna University of Technology
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