Institute of Production Engineering and Laser Technology · Institute of Production Engineering and...
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Page 1 Institute of Production Engineering and Laser Technology Vienna University of Technology Institute of Production Engineering and Laser Technology Univ. Prof. DI. Dr. F. Bleicher 16. Sept. 2010 Future technologies and new machine tool research activities
Transcript of Institute of Production Engineering and Laser Technology · Institute of Production Engineering and...
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Institute of Production Engineeringand Laser Technology
Univ. Prof. DI. Dr. F. Bleicher 16. Sept. 2010
Future technologies and new machine tool research activities
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Main topics at the IFT
Institute of Production Engineering and Laser Technology
Head: Univ. Prof. Dr. F. Bleicher
Area of Research Cutting TechnologyUniv.Prof.Dr. F. Bleicher
Area of ResearchLaser- und Forming Technology
N.N.
Laboratory for Precision Measuring
Univ. Prof. Dr. N. Durakbasa
Computer IntegratedManufacturing
Univ. Prof. Dr. B. Kittl
ProductionEngineering
Univ. Prof. Dr. F. Bleicher
Industrial MetrologyUniv. Prof. Dr. N. Durakbasa
IntelligentManufacturing
SystemsUniv.Prof. Dr. B. Katalinic
Laser and FormingTechnology
Univ.Prof. Dr. G. Liedl
NC-Controls Mechatronics Production Control MES ERP
Quality Management Production Metrology Nano-Metrology GPS - Geometrical
Product Specification
Laser Manufacturing Laser supported Forming Laser development Laser optic development
Production Automation Process Technology Cutting Technologies Machine tool Industrial robotics
Production SystemAnalysis and Design
Layout Planning Facility Concepts Robotics Technology - Innovation
Laboratory of ProductionEngineering
DI Bernreiter
Laboratory of Machining Technology
Dr. R. Mertz
Laboratory for Laser and FormingTechnology
Univ. Prof. Dr. G. Liedl
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Institute of Production Engineering and Laser TechnologyVienna University of 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
Research work at the IFT
Production EngineeringUniv. Prof.Dr. F. Bleicher
Production Automation 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
Technology 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
Machine Tool
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Research and experimental development
IT-basedproductionmanagement and quality assurance O
ptim
izat
ion
and
enha
ncem
ents
of i
ndus
trial
appl
icat
ions
model based description and simulation
experimental development
technology and processes
productionsystems and controltechnology
main topics
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Machining brittle hard materials - fly wheel test
entry zone B1
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
High performance deep-hole drilling
PCD - Position controlled drillingPFA - Pulsative feeding actuator
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Electrochemical milling
gap
dist
ance
in [µ
m]
pulse width in [µm]
Process precision defined by width of electric pulse
Source:
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Robotics Flexible Automation
Robot Aided Reconfiguration
RAR
Rai
lway
indu
stry
Veh
icle
Indu
stry
Flexible automation
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Machine tool concepts – since 2000
prod
uctiv
ity[p
arts
/yea
r]
flexibility
300.000
transfer line
flexible transfer line flexible
manufacturingsystem
flexible manufacturing
cell
machiningcenter
NC-machine
effici
ency
costs
required spaceenergy consumption
overall lifecycle costs
prec
ision
relia
bility
total cost of ownership
transfermachining center
double spindlemachining center
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Transfer machining centerInline transfer technology Inverse machining technology
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Design of new machine tool concepts
Parallel kinematics: X-CUT
Robot machining
ExechonTricept
Quickstep (Tripod)
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Calculation of static and dynamic system features
Coupled simulation – mechanics/control
right lowerslide
rightupper slide
Mechanical structure transferred to Matlab/Simulink©
Substituted mechanicalsystem
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Exhausting system - simulation of MQL
Air flow speed distribution in the XY plane
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Energy profile – energy efficient machine tools
process
material - work piece - tool
cutting edge geometry
feed rate
infeed
…
periphery
pneumatic- pressure- air consumption- operating cycle
hydraulic- fill level- temperature
automation
chip conveyor
• ...
machine
axis:- current- friction- circularity- parallel feed
spindle- vibration- torque- rotational
speed
…
axis
tool changer
chip conveyor
spindle
automation
… …
pneumatic
hydraulic
Regulations available or in preparation:
ISO 14001, ISO 16001 Environmental management systemISO 14062 Life cycle assesmentISO 14955 Environmental evaluation of machine tools
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Energy profile - machine tools
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
curre
nt[A
]
3 4
1
210
20
30
40
50
time [s]20 50 100 150 200 250 300
Determination of energy profile
Experimental setup on the machine tool VF 3 Haas
S … Apparent power [W]
P … Effective power [W]
Q … Idle power [W]
η … Efficiency
… Volume flow [l/min] – compressed air
… Volume flow [l/min] - lubrication1 spindle ramp-up2 4 contact width: ae= 2mm, 4mm3 fast feed motion
Machining (motion and conrol)Process cooling/conditioningTool and part handling
Waste handling and transportation
Machinecooling/heating23,3% 58,2%
ISO TC 39/WG 12
3,5%3,7%
11,3%
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
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
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Integrated diagnostics system
ball bar test
universal axis test axis synchron test
axis monitoring
trend analysis
after breakdown
predetermined
condition based
predictive
diagnostics
Improved maintenance strategy and new business models
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Integrated monitoring system
Drehmom
ent [Nm]
0
50
100
150
200
250
300Max. DrehmomentMittl. Drehmoment
Energie [kWh]
0
10
20
30
40
50
60
Hauptspindel
Linearachse
Rundachse
eugwechseler
rgungseinheit
Leitungen
Sonstiges
Belastungsprofile
Energieverbrauch
Ausfallkosten
TCO‐Datenbank
Berichts‐wesen
Aufzeichnung
Garantie‐vereinbarung
TCO‐Daten
reporting
recording
life cycle data
database guarantee agreement
load profile
energy consumption
breakdown costs
energy consuption diagnostics / analysis of load collectives preventive maintenance overall life cycle costs
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Overall process monitoring and optimization
days
hours
seconds
m-seconds
process energy consumption
value and non value addedenergy consumption
feature based energy consumption
daily energy consumption
feature 1 feature 3 feature 5
feature 4feature 2
value added
non valueadded
non valueadded
eP-Satellite
SAP Q-DAS
client
machine
drive
machine
IMDePS-client
machineuser data
control data
Machinelevel
ERP level
MES level
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Institute of Production Engineering and Laser TechnologyVienna University of Technology
Contact
Institute of Production Engineeringand Laser TechnologyKarlsplatz 131040 WienAustria
Tel.: +43-(0)1-58801-31101Fax: +43-(0)1-58801-31199
E-Mail: [email protected]: http://www.ift.at
