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Institute of Production Engineeringand Laser TechnologyFuture technologies and new machine toolresearch activitiesUniv. Prof. DI. Dr. F. BleicherInstitute of Production Engineering and Laser TechnologyVienna University of Technology16. Sept. 2010Page 1
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 2
Main topics at the IFTInstitute of Production Engineeringand Laser TechnologyHead: Univ. Prof. Dr. F. BleicherIndustrial MetrologyUniv. Prof. Dr. N. Durakbasa Quality Management Production Metrology Nano-Metrology GPS - GeometricalProduct SpecificationLaboratory forPrecision MeasuringUniv. Prof. Dr. N. DurakbasaArea of ResearchCutting TechnologyArea of ResearchLaser- und Forming TechnologyUniv.Prof.Dr. F. BleicherN.N.Computer IntegratedManufacturingProductionEngineeringUniv. Prof. Dr. B. KittlUniv. Prof. Dr. F. Bleicher NC-Controls Mechatronics Production Control MES ERP Production Automation Process Technology Cutting Technologies Machine tool Industrial roboticsLaboratory ofProductionEngineeringDI . Dr. B. Katalinic Production SystemAnalysis and Design Layout Planning Facility Concepts Robotics Technology - InnovationLaboratory ofMachining TechnologyDr. R. MertzInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyLaser and FormingTechnologyUniv.Prof. Dr. G. Liedl Laser Manufacturing Laser supported Forming Laser development Laser optic developmentLaboratory for Laserand FormingTechnologyUniv. Prof. Dr. G. LiedlPage 3
Research work at the IFTProduction EngineeringUniv. Prof.Dr. F. BleicherProduction AutomationTechnology Machine control concepts Optimisation of controlsystems NC programming andsimulation, CAM Software technology formechanical engineering Flexible automation Machinery system integration Robotics in buildingconstructoion Production metrology Research of static, dynamicand thermal behaviour ofmachine tools Cutting technologies withgeometrically defined andundefined cutting edges Forming technologies Assembly methods Basic research in processes Process analysis andoptimisation Analysis of tool wear Application of coolinglubricants Dry machining Metrological process analysisand assessmentMachine Tool Development of standardand new machine toolsconcepts Design, calculation andsimulation of machine tools(CAD-FEM) Metrological analysis andassessment of machine toolbehaviour Optimisation of mechanicalcomponents by use of: Simulation (FEM) Static and dynamicanalysis Energy efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 4
model based description andsimulationmain topicsOptimization and enhancements of industrialapplicationsResearch and experimental developmentexperimental developmenttechnology andprocessesproductionsystems andcontroltechnologyIT-basedproductionmanagement andquality assuranceInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 5
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 6
Hybrid machining – US-assisted machining Machining of brittle hard or difficult to machine materialsPiezo element driven vibrating systemsSingle axis system: amplitude max. 11µm at 13,44 kHz up to 21kHzDual axes system: amplitude max. 20µm at up to 500 HzSingle axis systemDual axes systemInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 7
Machining brittle hard materials - fly wheel testentry zoneB1Institute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 8
High performance deep-hole drillingPCD - Position controlled drillingPFA - Pulsative feeding actuatorInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 9
Electrochemical millinggap distance in [µm]Process precision defined by width of electric pulsepulse width in [µm]Source:Institute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 10
Flexible automationRailwayindustryVehicle IndustryFlexible AutomationRoboticsRobot Aided ReconfigurationRARInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 11
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 12
Machine tool concepts – since 2000transfermachining centerdouble spindlemachining centertransfer line300.000flexibletransfer iblemanufacturingcellNC-machinerequired spaceenergy consumptiontotal cost of ownershipoverall lifecycle costsprecis ire onliabief lityficiencyproductivity [parts/year]costsflexibilityInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 13
Transfer machining centerInline transfer technologyInverse machining technologyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 14
Design of new machine tool conceptsParallel kinematics: X-CUTQuickstep (Tripod)Robot machiningExechonTriceptInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 15
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 16
Coupled simulation – mechanics/controlCalculation of static and dynamic system featuresSubstituted mechanicalsystemMechanical structure transferredto Matlab/Simulink right lowersliderightupper slideInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 17
Exhausting system - simulation of MQL Air flow speed distribution in the XY planeInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 18
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 19
Energy profile – energy efficient machine toolspneumaticaxismachineprocessautomation material- work piece- tool cutting edgegeometrytool changer infeed spindle- vibration- torque- rotationalspeed feed ratespindlehydraulic axis:- current- friction- circularity- parallel feedperiphery pneumatic- pressure- air consumption- operating cycle hydraulic- fill level- temperature automation chipconveyor .chip conveyor Regulations available or in preparation:ISO 14001, ISO 16001 Environmental management systemISO 14062 Life cycle assesmentISO 14955 Environmental evaluation of machine toolsInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 20
Energy profile - machine toolsInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 21
Determination of energy profileMachining (motion andconrol)Process cooling/conditioningExperimental setup on the machine tool VF 3 Haas3,5%11,3%3,7%50Tool and part handling158,2%23,3%current [A]40Machinecooling/heatingWaste handling andtransportationISO TC 39/WG 1230S Apparent power [W]2043P Effective power [W]210Q Idle power [W]2050100150200time [s]2503001spindle ramp-up2 4 contact width: ae 2mm, 4mm3fast feed motionη Efficiency Volume flow [l/min] – compressed air Volume flow [l/min] - lubricationInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 22
Outline1Profile of the IFT2New technologies3Innovative machine tool concepts4Model based system design5Eco-design of machine tools6Overall efficiencyInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 23
Integrated diagnostics systemtrend analysisball bar testaxis monitoringdiagnosticspredictiveuniversal axis testaxis synchron testcondition basedImproved maintenance strategy andnew business modelspredeterminedafter breakdownInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 24
Integrated monitoring system300recordingAufzeichnungDrehmoment [Nm]250BelastungsprofileloadprofileMax. DrehmomentMittl. antie‐guaranteevereinbarung5040Energie [kWh]agreementlife selerRundachseLinearachseHauptspindel energy consuption diagnostics / analysis of load collectives preventive maintenance overall life cycle costsInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 25
Overall process monitoring and optimizationdaily energy consumptionERP levelePSatelliteclientdaysfeature based energy consumptionSAPfeature 4feature 2Q-DASfeature 1feature 3feature 5hoursvalue and non value addedenergy consumptionnon valueaddedMES levelmachineMachinelevelmachinenon valueaddedvalue addedsecondsePS-clientIMDcontrol datamachineprocess energy consumptionuser datadrivem-secondsInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 26
ContactInstitute of Production Engineeringand Laser TechnologyKarlsplatz 131040 WienAustriaTel.: 43-(0)1-58801-31101Fax: 43-(0)1-58801-31199E-Mail: [email protected]: http://www.ift.atInstitute of Production Engineering and Laser TechnologyVienna University of TechnologyPage 27
Institute of Production Engineering and Laser Technology Vienna University of Technology Integrated monitoring system Drehmoment [Nm] 0 50 100 150 200 250 300 Max. Drehmoment Mittl. Drehmoment Energie [kWh] 0 10 20 30 40 50 60 Hauptspindel Linearachse Rundachse eugwechseler rgungseinheit Leitungen
