From the economic point of view, rising the output rate of processing machines is a key requirement. Thereby, particular demands are to be met, i.e., product quality, process stability, energy consumption, impact of surroundings, or safety at work. Rising the output rate is limited, if only one of these demands can not longer be met. In this paper, a novel control approach is presented that allows to change the executed motion profile due to the actual output rate. Increasing the machine’s performance is evaluated on experimental results. Unused potentials of servo drives are opened up to generate highly dynamic multi-axis motions in processing machines.

The subject of this splitted article is the commissioning of a new application that may be part of a processing machine. At the example of the intermittent transport of small sized goods, for example, chocolate bars, ideas for increasing the maximum machine performance are discussed. Therefore, optimal process motion profiles are synthesised with the help of a computer simulation. In the first part of the paper, the modelling of the process was shown. This second part focusses on implementing the simulated motion approaches on an experimental test rig, whereby the new motion approach is compared to the conventional approach. Hence, the increasing of the performance can be proven. Eventually, possibilities for an online process control are observed which are necessary to prevent unstable process conditions.

The subject of this splitted article is the commissioning of a new application that may be part of a processing machine. Considering the example of the intermittent transport of small-sized goods, for example, chocolate bars, ideas for increasing the maximum performance are discussed. Starting from an analysis, disadvantages of a conventional motion approach are discussed, and thus, a new motion approach is presented. For realising this new motion approach, a virtual process model has to be built, which is the subject of this article. Therefore, the real process has to be abstracted, so only the main elements take attention in the modelling process. Following, important model parameters are determined and verified using virtual experiments. This finally leads to the possibility to calculate useful operating speed-dependent trajectories using the process model.

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