Add-on Error Compensation Unit as Sustainable Solution for Outdated Milling Machines

Kianinejad, K.; Thom, Simon; Kushwaha, Shashwat; Uhlmann, Eckart

doi:10.1016/j.procir.2016.01.094

Cited by 10 publications

(6 citation statements)

References 4 publications

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“…At the IWF, the active compensation unit shown in Fig. 1, was developed as an add-on for outdated machine tools to increase the working accuracy [15]. This is achieved by compensating geometrical errors.…”

Section: Active Error Compensation Unitmentioning

confidence: 99%

Accuracy in Force Estimation Applied on a Piezoelectric Fine Positioning System for Machine Tools

Uhlmann¹,

Polte²,

Triebel³

et al. 2021

Journal of Machine Engineering

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In order to improve the accuracy of machine tools, the use of additional active modules meeting the requirements of the "Plug & Produce" approach is focused. In this context one approach is the installation of a high precision positioning table for online compensation of machine tool deflections. For the model-based determination of the deflection, the knowledge of the effecting process force is crucial. This article examines the use of displacement sensors for force estimation in a piezoelectric system. The method is implemented on a high precision positioning table applicable in milling machine tools. In order to compensate nonlinear effects of piezoelectric actuators, a hysteresis operator is implemented. Experimental investigations are carried out to quantify the influence of preload stiffness, preload force and workpiece weight. Finally, a resolution d ≤ 78 N could be achieved and further improvements to meet the requirements for online compensation of machine tool deflection are discussed.

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Section: Active Error Compensation Unitmentioning

confidence: 99%

Accuracy in Force Estimation Applied on a Piezoelectric Fine Positioning System for Machine Tools

Uhlmann¹,

Polte²,

Triebel³

et al. 2021

Journal of Machine Engineering

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“…At the manufacturing cell level, lifetime-extending add-ons for machine-tools (Kianinejad et al 2016) and of automated workplaces preventing musculoskeletal strain by workers (Krüger and Nguyen 2015), can be cited as examples.…”

Section: Manufacturing Technologiesmentioning

confidence: 99%

Field of Research in Sustainable Manufacturing

Bonvoisin

Stark

Seliger

2017

Sustainable Production, Life Cycle Engineering and Management

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Sustainability has raised significant attention in manufacturing research over the last decades and has become a significant driver of the development of innovative technologies and management concepts. The current chapter aims to provide a structured overview of the wide field of research in sustainable manufacturing with a particular focus on manufacturing technology and management. It intends to describe the role of manufacturing in sustainability, outline the complementary approaches necessary for a transition to sustainable manufacturing and specify the need for engaging in interdisciplinary research. Based on a literature review, it provides a structuring framework defining four complementary areas of research focussing on analysis, synthesis and transition solutions. The challenges of the four areas of research manufacturing technologies ("how things are produced"), product development ("what is being produced"), value creation networks ("in which organisational context") and global manufacturing impacts ("how to make a systemic change") are highlighted and illustrated with examples from current research initiatives.

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“…By upgrading or enhancing the functionality of outdated machine tools rather than replacing them with new machines, valuable resources can be saved (Allwood et al 2011). The add-on solution developed helps to keep outdated machine tools competitive in the contemporary production chain by increasing not only positioning accuracy, but also by allowing for active vibration control to reduce chatter (Kianinejad et al 2016). The energy efficiency for different machining operations of an outdated milling machine and a modern one was compared in (Kianinejad et al 2015).…”

Section: Add-ons For Machine Tool Upgradementioning

confidence: 99%

“…In order to use the error compensation table depending on the respective manufacturing tolerances and to allow sharing with different machine tools, the main challenge with the integration of an error compensation table is to provide easy-to-install capabilities. These capabilities are achieved by independent control, as only one interface is required to the machine tool for sensor readouts, along with a screw connection of the table, see also (Kianinejad et al 2016). The error compensation table corrects the relative position between workpiece and tool in real time and provides compensation in two perpendicular axes in the horizontal plane (see Fig.…”

Section: Add-ons For Machine Tool Upgradementioning

confidence: 99%

“…To overcome the problem of stick-slip and backlash, the error compensation table is designed to be monolithic, featuring compliant joints which provide high stiffness up to k z = 100 N/µm in the vertical direction (Kianinejad et al 2016). In order to provide high strain by low stress in the compliant joints, aluminum alloy (AW7075) was chosen due to its high ratio of strength to elastic modulus.…”

Section: Add-ons For Machine Tool Upgradementioning

confidence: 99%

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Sustainable Solutions for Machine Tools

Uhlmann

Lang

Prasol

et al. 2017

Sustainable Production, Life Cycle Engineering and Management

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Environmental, economic and social changes of any significant proportions cannot take place without a major shift in the manufacturing sector. In today's manufacturing processes, economic efficiency is realised through high volumes with the use of specialised machine tools. Change in society, such as in the form of mobility and digitisation, requires a complete overhaul in terms of thinking in the manufacturing industry. Moreover, the manufacturing industry contributes over 19 % to the world's greenhouse gas emissions. As a consequence of these issues, a demand for sustainable solutions in the production industry is increasing. In particular, the concept of "cost" in manufacturing processes and thus the "system boundaries" within the production of the future has to be changed. That is, a great number of aspects to the machine tool and production technology industries can be improved upon in order to achieve a more sustainable production environment. Within this chapter, the focus lies on microsystem technology enhanced modular machine tool frames, adaptive mechatronic components, as well as on internallycooled cutting tools. An innovative machine tool concept has been developed recently, featuring a modular machine tool frame using microsystem technology for communication within the frame, which allows for a high level of flexibility. Furthermore, add-on upgrading systems for outdated machine tools-which are particularly relevant for developing and emerging countries-are poised to gain in importance in the upcoming years. The system described here enables the accuracy of outdated machine tools to be increased, thus making these machine tools comparable to modern machine tool systems. Finally, the cutting process requires solutions for dry machining, as the use of cooling lubricants is environmentally damaging and a significant cost contributor in machining processes. One such solution is the use of internally cooled cutting tools.

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Add-on Error Compensation Unit as Sustainable Solution for Outdated Milling Machines

Cited by 10 publications

References 4 publications

Accuracy in Force Estimation Applied on a Piezoelectric Fine Positioning System for Machine Tools

Accuracy in Force Estimation Applied on a Piezoelectric Fine Positioning System for Machine Tools

Field of Research in Sustainable Manufacturing

Sustainable Solutions for Machine Tools

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