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Mechatronic Systems for Machine ToolsR. Neugebauer1(1), B. Denkena2(2), K. Wegener3(2)1Fraunhofer-Institute for Machine Tools and Forming Technology IWU, Chemnitz, Germany2Institute of Production Engineering and Machine Tools (IFW), Hannover University, Garbsen, Germany3Institute of Machine Tools and Manufacturing (IWF), ETH, Zurich, SwitzerlandAbstractThis paper reviews current developments in mechatronic systems for metal cutting and forming machinetools. The integration of mechatronic modules to the machine tool and their interaction with manufacturingprocesses are presented. Sample mechatronic components for precision positioning and compensation ofstatic, dynamic and thermal errors are presented as examples. The effect of modular integration of mecha-tronic system on the reconfigurability and reliability of the machine tools is discussed along with interventionstrategies during machine tool operation. The performance and functionality aspects are discussed throughactive and passive intervention methods. A special emphasis was placed on active and passive damping ofvibrations through piezo, magnetic and electro-hydraulic actuators. The modular integration of mechatroniccomponents to the machine tool structure, electronic unit and CNC software system is presented. The pa-per concludes with the current research challenges required to expand the application of mechatronics inmachine tools and manufacturing systems.KeywordsMachine tool, Mechatronic, Adaptronic1 INTRODUCTIONThe technological transformation of the information soci-ety is associated with considerable changes in the de-mands on machine tools, requiring new solutions for theinherent conflict in design between precision and produc-tivity 123. Future performance requirements of ma-chine tools will be characterised by trends in microsys-tems technology and nanotechnology. For mechanicalmanufacturing, this results in constantly growing de-mands for precision in machine tools (Fig. 1). The scien-tific and technical challenge does not lie entirely in thecapability to produce mechanical structures with evergreater precision, but also mass produced workpieces atreasonable production costs.Globalisation is putting mechanical production in high-wage countries under immense economic pressure 2.One fundamental initiative to find a solution in the area ofprocess development is the shortening of process chainsby technology substitution. This must be accomplished byincreasing the precision of highly productive procedures,since increasing the productivity of high-precision proce-Figure 1: Machining capability over time 4.dures is mostly limited by the underlying physical princi-ples of those procedures.Consequently, it can be deduced that the contradictionposed by the demands for productive precision in largeworking areas and flexible, reliable manufacturing re-quires a universal system architecture for machine toolswith the typical properties of mechatronic systems con-version capability (reconfigurability) and self-optimisation(immunity to disturbance) 5.The concrete demands identified from surveys of cus-tomers and manufacturers in this respect 2 are:An increase in availability as a result of prescientmaintenance; status and process monitoring; intelli-gent maintenance; diagnostic functions.Highly economic manufacturing (life-cycle costs) as aresult of function-oriented design; improved perform-ance due to dynamics, flexibility as a result of recon-figurability.These factors are of necessity associated with:A high level of standardisation and modularisation:interfaces, technology modules, independent func-tional assemblies.Efficient control systems.In recent decades, mechatronics has become establishedas a developmental method for such systems and todayconstitutes the key discipline in production technology 6.The term mechatronics was coined in 1969 by the com-pany Yaskawa Electric Cooperation to signify the exten-sion of the function of mechanical components by meansof electronics. As a result of the immense speed of devel-opments in information processing, the aspect of integrat-ing “intelligence” in technical systems in mechanical engi-neering is now increasingly at the forefront. Mechatronicsystems are essentially characterised by the function-oriented expansion of a mechanical system by the spatialand/or functional integration of sensors and actuators andthe use of a control system to guarantee functionality 7.The benefits of mechatronics go beyond a mere additiveeffect, as is emphasised by the definition given in 8:Annals of the CIRP Vol.56/2/2007doi:10.1016/j.cirp.2007.10.007PassiveStructure“Mechatronicsneeds.asynergeticcross-fertilizationbetween the different engineering disciplines involved:mechanical engineering, control engineering, microelec-tronics and computer science. This is exactly whatmechatronics is aiming at; it is a concurrent-engineeringview on machine design.”The term “adaptronics” was coined in the 1980s in theUSA. Under the umbrella of this term, developments inmaterials science and engineering were begun whichwere inspired by bionic construction principles, as in thestructure of a human muscle, aimed at producing efficientlightweight structures for air and space travel by means ofdirect integration of transducer materials acting as sen-sors and actuators in the construction material itself (Fig.2). Transducer materials which are used include piezoceramics, shape memory alloys, magnetostrictive materi-als or electromagnetically activated fluids and polymers.By connecting composite components acting as sensorsand actuators, using appropriately adapted electroniccontrols, the structural dynamics properties of the basicmechanical structure can directly be influenced. One ma-jor application area is vibration control in lightweight struc-tures, extending as far as ASAC - Active StructuralAcoustic Control 9. Today, the initiatives to find solutionsfeaturing distributed integration of these materials in con-struction materials to form an active composite materialby means of complex mechanical and information tech-nology are only just beginning and are currently the sub-ject of intensive research 10.The use of actuators made from transducer materials inhighly integrated mechatronic components, such as pre-cision positioning systems, is technically more advancedand already employed in industrial applications. If suchcomponents use integrated sensors for autonomous im-provement of higher-level mechanical or mechatronicstructures, they are defined in the vocabulary of mechani-cal engineering as adaptronic 11.In future, mechatronics will be fundamentally enriched byoptical technologies as a new basic system type. Eventoday, they are established directly in machine tools viathe laser beam, as an alternative machine drive and toolfor mechanical processing.MechanicalSystemsMechatronicSystemsAdaptronicSystems3. Optics as the universal new basic system type.The basic approach of mechatronics is inherently an-chored in the development of machine tools. The elec-tronically controlled movement behaviour of a mechanicalstructure was first implemented in machine tools in 1952with the first NC control system made at MIT. Since the1970s, mechatronics has fundamentally changed thefunctionality and efficiency of machine tools as a result ofthe increasing integration of NC movement controls andthe automation of processes. In order to be able to makeoptimum use of the modern technical options offered bymechatronics, modified processes 7 and tools 13 arerequired for a unified design. These are described in de-tail in Chapter 2. In particular, a change in the designparadigm is needed to prevent the inevitable increase insystem complexity due to the increased functionality frommechatronics resulting a priori in a decrease in reliability.Because of the differing scale and bandwidth of machineerrors (Fig. 3), it makes sense for the further developmentof the machine tool mechatronic system to adhere to ahierarchical conceptual framework.CompensationMethodsMechatronic/AdaptronicComponentsModelbasedwithinherentActuatorsCalibratiFigure 3: Bandwidth of machine tool errors and optionsfor intervention.In doing so, it is possible to distinguish the following sys-tem levels:1 The machine tool mechatronic system.Component sensors and the lowest possible number ofadditional sensors capture an image of process and ma-chine that approximates to reality. With the support ofSystemAnswerActuatorsSystemAnswerSensorsSystemAnswermodels, the intrinsic drives of the machine tool are usedby the control system to correct processing errors. Theprimary application for which this is suitable today in-volves quasi-static error sources, such as thermally de-termined displacements or calibration of machines. How-ControlControlever, the comprehensive data from the sensors also pro-Figure 2: Characteristics of mechatronic systems.Optical waveguides permit interference-free communica-tion between sensors, information processes and actua-tors with high bandwidths. Sensors based on optical prin-ciples, including industrial image processing, achieve thevery highest information density. At the same time, thespeed of data processing by optoelectronics will furtherincrease in the future.The following can therefore be identified as driving thefurther development of mechatronics technology andhence, as a consequence, the development of machinetools:1.Information technology based on Moores law12.2.Adaptronics (and the associated manufacturing proc-esses of microsystem technology) for lightweight con-struction and for increasing the level of integration ofthe components.vide initiatives for increasing the reliability and availabilityof the machine tool. The increasing importance of solu-tions of this kind is a consequence of the high speed ofdevelopment of CNC technology. They are strongly influ-enced by design and system integration and are detailedin examples in Chapters 2 and 4.2 The mechatronic components of the machine tool.These include in particular the main and feed drives. Pastresearch work has concentrated on this system level andhas already been analysed and published in detail. Thesecomponents and their integration in terms of informationtechnology define the capability of the actuator and thebandwidth of the solution initiatives in system level 1. Ma-jor progress can therefore be expected as a result of op-timum system integration (Chapter 4).3 The integration of additional mechatronic solutions inmachine tool components.PassiveStructureActuatorsSensors300natural oscillations ofthe machine foundation100ontransfer0drive errorsnaturaloscillations of themechanicselastic deformationsby process- andinertial forcesthermal behaviourgravitationfrequency / HzPassiveStructure-The aim of intervention in this system level is toimprovemachinetoolmalfunctionsbymeansofautonomous components which either act directly asancillary drives to compensate for dimensional errorsnear to the source of the interference, or to improve thebehaviour of the con- trolled process of the basicstructure of a machine tool component for the higher-level control system. The ad- vantage of this kind ofsystem intervention lies in a design which is optimallyadapted to the local problem and the consequentremoval of restrictions with regard to the bandwidth ofmalfunctions to be compensated. As Plug & Playmodules, such solutions are interesting for the im-plementation of reconfigurability. These are the focus ofChapter 3.In relation to the overall function of the machinetool,theabovesystemlevels,whicharenotindependent, have both a specific suitability for use and,at the present time, different levels of advancement inapplication. The opti- mum effect can therefore only beachieved with thorough system integration concepts(Chapter4),whichtakeintoaccountboththemechanical involvement and the signal and energyflows,butaboveallthearchitectureofthedataprocessing.Examplesofoptimisationcriteriacon-taining fundamental parameters, including economic pa-rameters, are the Plug & Play capability, the energy effi-ciency and the reliability of the overall solution.3CONCLUSIONMechatronicsenablesasupremedevelopmentmethod- ology for machine tools. The technologicaldevelopments in theindividual domains of the basicstructuremechan-ics/materials,transformationsystems sensor/actuator systems and data processingwill characterise the future development of “intelligent”machine tools. Over the next few years, the emergingtrends will be the increasing use of self-optimising, in partadaptronic components and the use of ever more efficientcontrol systems for model- supported compensation ofmachine errors and process control. All functionality ofmachines will become elec- tronically enhanced and thusmechatronic functions.Reconfigurability as a necessary pre-requisite for theflexibility of machine tools demands mechatronic machinetool components with Plug & Play functionality. This re-quires the creation and standardisation of interfaceswhich are uniform in terms of their mechanical, energyand information technology aspects. These machine toolcomponents must at the same time be strictly function-oriented in their design. They must be subjected to acomprehensive description of their functionality in termsof both hardware and software structures. Analogies withdevelopments in computer technology or robotics will be-come more prominent.In our vision of the future, the boundaries betweenrobot- ics and machine tools will become diffuse inmechatronic manufacturing resources. This trend will gohand in hand with a fundamental transformation in termsof kinematic structures, but above all in the architectureof control sys- tems. One of the major challenges will beto guarantee the reliability of these mechatronic systemsin order to meet economic demands in terms of theavailability of production systems.The challenge is