Further development and implementation of a model-based, integratable multi-sensor system for automatic and process parallel determination and compensation of the volumetric error at the functional point (AutoKomp II)

进一步开发和实施基于模型的可集成多传感器系统，用于自动和过程并行确定和补偿功能点的体积误差（AutoKomp II）

• 批准号: 298597595
• 负责人: Professor Dr.-Ing. Robert Schmitt
• 金额: --
• 依托单位: Forschungsbereich Fertigungsmeßtechnik und Qualitätsmanagement
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/298597595?language=en
• 关键词: Further; development; implementation; model; based

The trend in production technology towards more efficient component manufacturing with increasingly complex geometries and shrinking tolerances is unbroken due to the advancing technological development. The positioning accuracy of the machine tool is essential for component quality. Any deviation of the machine movement from the nominal movement at the functional point (volumetric error) is transferred to the workpiece and results in shape deviations. A state of the art industrial method for increasing precision without cost-intensive design changes or mechanical settings is the calibration of the machine tool, i.e. measuring the machine errors, with subsequent control-based compensation. Since the movement deviations of the machine tool vary depending on the process, temperature, load and wear, static compensations lose their validity within short periods of time (in extreme cases a few hours). Although regular repetitions of the calibration are established in industry, they are insufficient due to the high variability of the motion deviation and at the same time cause high costs. In addition, there are numerous methods in research and industry to compensate for the variability of individual geometric errors. Still, there is no overall model for the practical application to all relevant static and elastic effects. To maximize the economic benefit of calibrations and to avoid costly and energy-intensive air conditioning, time-discrete calibrations and the process-parallel recording of machine states as well as the different modelling approaches should effectively combined. The aim of the second phase of the overall project applied for here is the further development and implementation of a model-based, integratable multi-sensor system for automatic and process parallel determination and compensation of the volumetric error at the functional point. Based on the sensor design for the process-parallel detection of geometric errors within a linear axis, which was developed and validated in phase one, the entire test machine is to be equipped with appropriate sensors. In addition, further sensors will be used to record machine and environmental conditions, such as the deformation of structural components and temperature distribution. Direct measurements of the volumetric error will be added as time-discrete inputs for the setup, adjustment and validation of an overall model, whereby the time intervals for this must be maximized. This multi-sensor system then provides data for a hybrid overall model approach, which on the one hand takes into account existing and industrially established methods, but also attempts to combine the advantages of modern white-box and black-box modelling. The project will be tested and validated on a test machine for one year before it is to be transferred to other machine types and into productive operation in phase three.

由于技术的发展，生产技术朝着更加复杂的几何形状和越来越复杂的几何形状和缩小的公差缩小的趋势是不间断的。机床的定位精度对于组件质量至关重要。机器运动与功能点标称运动的任何偏差（体积误差）都会转移到工件上，并导致形状偏差。在没有成本密集的设计更改或机械设置的情况下，提高精度的艺术工业方法是机床的校准，即测量机器误差，并随后基于控制的补偿。由于机床的运动偏差因过程，温度，负载和磨损而异，因此静态补偿会在短时间内失去有效性（在极端情况下几个小时）。尽管校准的定期重复是在行业中建立的，但由于运动偏差的高度变异性，并且同时导致高成本，因此它们不足。此外，研究和行业中有许多方法可以弥补单个几何错误的可变性。尽管如此，对于所有相关的静态和弹性效应，实际上还没有总体模型。为了最大程度地利用校准的经济利益并避免昂贵和能源密集型的空调，时间二散的校准以及机器状态的过程并行记录以及不同的建模方法应有效合并。此处应用的整个项目的第二阶段的目的是进一步开发和实施基于模型的，可集成的多传感器系统，用于自动和过程并行确定和功能点上体积误差的补偿。基于在线性轴内的几何误差的过程平行检测的传感器设计，该轴是在第一阶段开发和验证的，整个测试机将配备适当的传感器。此外，还将进一步传感器记录机器和环境条件，例如结构成分的变形和温度分布。对于设置，调整和验证了整体模型的时间间隔，将添加体积误差的直接测量，从而将其时间间隔最大化。然后，该多传感器系统为混合整体模型方法提供了数据，该方法一方面考虑了现有的和工业上建立的方法，但也尝试结合现代白盒和黑色框建模的优势。该项目将在测试机上进行一年的测试和验证，然后将其转移到其他机器类型并在第三阶段中转移到生产性操作中。