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International Workshop on Advanced Motion control (AMC)

作者： Matthias Keinert Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools University of Stuttgart Stuttgart Germany

Computerized numerical controls are more and more executed on off-the-shelf system platforms and can thus benefit from the developments in the area of processor technology. Multi-core processors provide sufficient processing power for these controls but require a specific system design that allows exploiting the parallel processing unit. This paper presents an approach on how computerized numerical controls may be partitioned on a task and a functional level using task and data parallelism for the efficient execution on multi-core system platforms.

关键词： Computer numerical control Parallel processing Multicore processing Interpolation Software Real-time systems Time factors

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Application of Substructure Decoupling Techniques to Predict Mobile machine Tool Dynamics: Numerical Investigations

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Procedia CIRP 2016年 46卷 537-540页

作者： Mohit Law Hendrik Rentzsch Steffen Ihlenfeldt Matthias Putz Indian Institute of Technology Kanpur India Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz 09126 Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Germany

In situ machining of large workpieces is made possible by moving mobile machines to workpiece locations. To guide and enhance on site machining performance, dynamics of the assembled system must be predicted beforehand. Beforehand prediction of assembled response requires dynamics of the mobile machine in its free-free configuration be coupled with response of base/workpiece measured at location. Since obtaining the free-free response of the machine is non-trivial, this paper presents a substructure decoupling scheme that instead extracts the machine's response from known dynamics of the machine mounted on a base, and from information of a substructural base system. Simulation driven investigations show the decoupling scheme to be robust even under the vagaries of measurement noise and changes in the residual substructural base system. Extracted dynamics of the machine can be subsequently synthesized with known dynamics of other bases/workpieces for a priori prediction of assembled dynamics to guide first-time-right on site machining.

关键词： Dynamics machine tool Simulation Mobile machine Substructure decoupling

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On-line learning artificial neural networks for stability classification of milling processes

On-line learning artificial neural networks for stability cl...

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IEEE/ASME (AIM) International Conference on Advanced Intelligent Mechatronics

作者： Jens Friedrich Christoph Hinze Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart

ISBN: (纸本)9781509020669

For increasing the productivity in milling processes an estimation of the milling stability in dependency of critical parameters, such as spindle speed, cutting-depth and cutting-width is needed. In this paper an approach for online estimation of the milling stability classification via Artificial Neural Networks is provided. The network grows with the needs of the network and is trained with an Extended Kalman Filter. Some statistical training parameters are adapted during the training process and a first-order trust criterion is introduced to estimate the prediction quality of the network. The proposed network is capable for continuous online training with sorted input data. With the adaptive enhancements the training works well on analytical benchmark functions and with a 2-DOF milling stability simulation.

关键词： Stability criteria Milling Training Neurons Covariance matrices Kalman filters

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Influence of Parameter Uncertainties on the Computation of Stability Lobe Diagrams

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Procedia CIRP 2016年 46卷 460-463页

作者： Michael Löser Knut Großmann Institute of Machine Tools and Control Engineering TU Dresden Helmholtzstraße 7a 01069 Dresden Germany

To predict stability boundaries of cutting operations models of process forces and dynamic machine behavior are required. Uncertainties of model parameters may lead to significant differences between predicted and measured stability boundaries. To run a lot of simulations with random parameters is a possible approach to take these uncertainties into account when analyzing the stability behavior. However, this is a time consuming task. This paper presents a time efficient method to provide confidence levels of computed stability lobe diagrams based on stability analysis in frequency domain. The required computational time is compared to the effort for an explicit calculation with different stability algorithms. The confidence levels are compared to experimentally determined stability lobe diagrams.

关键词： milling simulation chatter stability lobe diagrams

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Online parameter identification for a linear parameter-varying model of large-scale lightweight machine tool structures with pose-dependent dynamic behavior

Online parameter identification for a linear parameter-varyi...

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IEEE/ASME (AIM) International Conference on Advanced Intelligent Mechatronics

作者： S. Apprich F. Wulle A. Pott A. Verl Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

ISBN: (纸本)9781509020669

Structural components of large lightweight machine tools with serial kinematics, travelling column and Gantry-type machine tools, feature a pose-dependent dynamic behavior. Conducting vibration reduction methods at these structures demands information on the precise current dynamic behavior. Determining this, an approach is presented, where the parameters of a simple rigid multi-body model of a lightweight travelling column machine tool structure are adapted online to the current dynamic behavior of the structure using a recursive least-squares estimator. Inherent control signals and additional acceleration sensor signals are used for the parameter updating. These signals are conditioned using Kalman and lowpass filters. The model as well as the online parameter identification algorithms are validated at a laboratory prototype of a lightweight travelling column machine tool. Experiments show that the model parameters quickly converge to a stable state after impulse excitation of the laboratory prototype with fixed axis. The parametrized model exactly represents the measured dynamic behavior of the laboratory prototype in a frequency range until 50 Hz. For moving axis the estimated parameters consistently change according to the movement of the axis.

关键词： machine tools Prototypes Random access memory Vibrations Mathematical model Parameter estimation Adaptation models

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A planning system for generating manipulation sequences for the automation of maintenance tasks

A planning system for generating manipulation sequences for ...

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IEEE International Conference on Automation Science and engineering (CASE)

作者： Christian Friedrich Armin Lechler Alexander Verl Institute of Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

ISBN: (纸本)9781509024100

The adaption of autonomous robots to complex assignments like automating maintenance tasks, requires the study of novel planning systems for task generation which use a priori and sensor-based data. This paper presents an approach to disassembly and assembly planning for automating maintenance tasks in production systems. The planning system combines CAD data with visual data from an RGB-D sensor. This allows the creation of a consistent environmental model, which can be used to plan a (dis)assembly task for an autonomous robot. The proposed method allows to compute manipulations directly in the task space of the robot. The algorithm uses a geometric and semantic reasoning concept to compute a relational graph which describes the individual degrees of freedom in-between the components. The proposed algorithm is highly time efficient, thus being particularly suited for the automation of maintenance tasks. With the additional integration of visual data, it is possible to compensate environmental uncertainty from the CAD data as well. This paper describes the planning architecture and algorithms in detail and concludes with an experimental validation.

关键词： Planning Maintenance engineering Robot sensing systems Solid modeling Semantics Automation

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Automated control System Generation Out of the Virtual machine

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Procedia Technology 2016年 26卷 349-356页

作者： Stefan Scheifele Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Seidenstr. 36 70174 Stuttgart Germany

To drastically reduce the commissioning time of a machine tool innovative companies rely more and more on the possibilities of virtual commissioning - commissioning of real controls on virtual machines and plants in order to improve the accuracy and robustness of acting programs. These virtual machines and plants require data defining their behavior and appearance. The mechanical engineering, which is focused on machine modules, uses engineering tools for configuration and parameterization of the needed control systems. These software tools have knowledge of the cross-relationships and dependencies of the individual modules to each other and derive the required data for the control systems (CNC, PLC, …) but also, e.g. the needed documents from a central database. It is desired to generate the required virtual machines and plants automatically and use them for the test of the control systems. In the research project “CassaMobile” a module is understood as a self-sufficient unit, which includes all mechanical and electrical components to fulfil the intended function and either has its own control system or is controlled by a central control system. The difference from engineering by commissioning lists is, that the control system receives a list of all available modules through a query of the physical machine and that the modules are explaining themselves to the control system and not by a central data base. This is made possible by a module-specific configuration memory such as the CIMory (Configuration and Information Memory). An automatic configuration of the control system on the basis of CIMory data has already been presented. This approach does not require a central data base out of which a virtual machine could be generated. However, the commissioning of the control system can be done only after the construction of the actual machine. To overcome this disadvantage, for “CassaMobile” a virtual equivalent was developed: by using the commissioning list, a virtual

关键词： Configuration and Information Memory (CIMory) virtual commissioning virtual ramp up virtual machine automated control system configuration

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Multi-level Energy Demand Optimizer System for machine Tool controls

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Procedia CIRP 2016年 41卷 783-788页

作者： Jan Schlechtendahl Philipp Eberspächer Philipp Schraml Alexander Verl Eberhard Abele Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) Seidenstraße 36 70174 Stuttgart Germany Institute of Production Management Technology and Machine Tools (PTW) Otto-Berndt-Str. 2 64287 Darmstadt Germany

The need to increase resource and energy efficiency for a sustainable production has led to saving potential analyses and afterwards saving strategies in a multitude of disciplines: product design, supply chain management, process chain design, production process development, energy-optimal machine or component control and even machine tool and component design. Each of those strategies resulted in numerous improvements, however, they still lack reciprocal consideration. To overcome this deficit, a machine-independent energy control system to include any control- or operation-based energy optimizer will be introduced in this paper. It is based on real-time control information from the machine and software-based energy demand optimizers targeting the machining process, the machine tool components control as well as the overlaying production process. The control system itself ensures the correct cooperative operation of the three optimizer types, to enable the much needed reciprocal consideration of the optimizer's effects.

关键词： Energy efficiency Optimization machine Tool

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Cloud-based control for downstream defect reduction in the production of electric motors

Cloud-based control for downstream defect reduction in the p...

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International Conference on Electrical Systems for Aircraft, Railway, Ship Propulsion and Road Vehicles & International Transportation Electrification Conference (ESARS-ITEC)

作者： D. Coupek A. Lechler A. Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (纸本)9781509008155

Classical computing is shifted gradually into the cloud, offering completely new possibilities in information usage, computing power and application of learning algorithms. In this paper, a cloud-based architecture of control systems is investigated showing the benefit for multi-stage production systems. All sequential manufacturing and assembly processes are connected via a cloud-based architecture, which allows using information from a previous production step in one of the subsequent steps for downstream deviation compensation. This strategy is applied to the rotor production of electric motors in the automotive industry, as the current production shows high defect rates due to the lack of adequate sensor signals and optimization algorithms. The magnetization process of permanent magnets is executed in saturation, so that the generation of deviations cannot be avoided by process control or process optimization. Instead, the variance in the magnetization signal must be compensated in a downstream process, here the rotor assembly stage. Project results show how such a cloud-based architecture can increase the product quality while decreasing the amount of scrap parts in a real industrial scenario, consequently saving valuable resources like energy and raw materials. Reduction of deviations is crucial for this emerging industrial sector as electric motor production for vehicles is moving towards mass production.

关键词： Cloud computing Rotors Electric motors Production systems Magnetization Optimization

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The control architecture RoViDiAsS — A robotic visual disassembly and assembly system

The control architecture RoViDiAsS — A robotic visual disas...

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IEEE International Conference on Industrial Technology (ICIT)

作者： Christian Friedrich Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (纸本)9781467380768

In highly automated and dynamic production systems the plant availability plays a crucial role, especially in terms of economic goals. In order to ensure a high system availability various maintenance strategies like preventive or predictive approaches are studied and applied. Through the increasing complexity of production systems, more and more methods for (semi-)automation of maintenance tasks are in use, especially for fault-diagnosis. Today, service or repairing tasks are usually performed by a human operator. To enable a flexible automation of different maintenance tasks this paper introduces the modular robot control architecture of RoViDiAsS (Robotic Visual Disassembly and Assembly System). RoViDiAsS combines CAD data from assembly models with vision system data for planning possible manipulations for an autonomous robot. The use of offline data from CAD and online data from the vision system enables the compensation of uncertainties as well as a suitable planning approach. RoViDiAsS is therefore divided into five function modules which handle different responsibilities from the management of the input data to controlling the different manipulations. The architecture is designed in a modular way, making it possible to integrate new functions and algorithms. This contribution describes the structure of the system architecture and closes with the preparation of experiments.

关键词： Solid modeling Maintenance engineering Robots Design automation Planning machine vision Production systems

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