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A Nonlinear Elasticity Model and Feedforward Compensation Method to Increase Positioning Accuracy of Industrial Robots

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IEEE Transactions on Automation Science and engineering 2025年

作者： Dzubba, Marcel Neubauer, Michael Hinze, Christoph Lechler, Armin Verl, Alexander University of Stuttgart Institute for Control Engineering of Machine Tools and Manufacturing Units Stuttgart70174 Germany

Large industrial robots are inexpensive compared to their workspace. Due to flexibility, the positioning accuracy is compromised. This paper presents a simple yet effective static calibration method for robots using a laser tracker that can be applied to processes with no change in external load and without high processing forces. The calibration method is based on a novel elastokinematic model that captures the nonlinear gearbox and link compliance and also accounts for the effects of pose dependent joint friction and nonlinearities due to the gravity compensation mechanism. Furthermore, a feedforward concept is presented that separates kinematics from compliance to reduce computation time. The calibration method was implemented on industrial hardware and experimentally validated on a KUKA KR210–2. In comparison to state of the art compliance modeling, accuracy is improved by 23.1 %. Finally, the feedforward model reduces the mean positioning error in the entire workspace by 54.9% compared to the purely kinematically calibrated model, emphasizing the need for compliance compensation. © 2004-2012 IEEE.

关键词： Kinematics

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Modeling Load-, Velocity-, and Temperature-Dependent Transmission Errors of Cycloidal Drives for Industrial Robots Using Fourier Series

Modeling Load-, Velocity-, and Temperature-Dependent Transmi...

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IEEE International Conference on Industrial Technology (ICIT)

作者： Christian J. E. Bauer Valentin Kamm Marcel Dzubba Lukas Steinle Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331521950

ISBN: (纸本)9798331521967

Industrial robots are rarely used for machining tasks due to their limited path accuracy. This accuracy is mainly limited by inaccuracies in the drive trains. Compliance and transmission errors occur in the joint gearboxes. While transmission errors have been extensively studied for strain wave gears, there is little research on these errors in cycloidal drives. This gearbox type is commonly used in industrial robots for medium to heavy payloads. It is proposed to model the mainly periodic transmission errors using a Fourier series where amplitude and phase are defined as a polynomial function of the main influence factors load-torque, velocity, and temperature. Measurements of the transmission errors were conducted using an experimental setup representing a single robot joint. In the evaluation of the measurement data, harmonic frequencies were related to mechanical properties of the cycloidal drive. These frequencies were used to identify the parameters of the polynomial Fourier series model. Compared to validation measurements, the derived model shows an average root mean square error of 0.026 mrad. It is proposed to use the output of the resulting model in a feedforward control approach to compensate the transmission errors and to increase the path accuracy of industrial robots.

关键词： Temperature measurement Accuracy Temperature Gears Measurement uncertainty Industrial robots Polynomials Frequency measurement Fourier series Load modeling

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Offline and Online Energy Simulation using Virtual Commissioning Models with Extended Dynamical Behavior

Offline and Online Energy Simulation using Virtual Commissio...

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2025 IEEE/SICE International Symposium on System Integration, SII 2025

作者： Deubert, Darius Pfeifer, Denis Scheifele, Christian Fehr, Jorg Verl, Alexander Bosch Rexroth AG Lohr am Main97816 Germany Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart70174 Germany ISG Industrielle Steuerungstechnik GmbH Stuttgart70563 Germany Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart70174 Germany

ISBN: (纸本)9798331531614

Considering energy consumption and dynamical behavior within the simulation of manufacturing systems emerges as an important objective for their development, commissioning, and operation. Currently, these aspects are often neglected in many fields including virtual commissioning. This work presents an approach to extend highly detailed virtual commissioning models of components from industrial automation by dynamics models for the calculation of energy consumption in an offline simulation and for reuse in an online simulation. To validate the presented approach, an exemplary offline virtual commissioning simulation of a pick-and-place robot application is implemented and subsequently transferred to an online simulation. The validation shows a good accuracy of the simulated energy consumption, enabling virtual commissioning engineers to analyze and optimize energy consumption already in the design phase of manufacturing systems. Additionally, the dynamical behavior was well reflected in the online simulation, contributing to the capability of simulation in the operation phase. © 2025 IEEE.

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Offline and Online Energy Simulation using Virtual Commissioning Models with Extended Dynamical Behavior

Offline and Online Energy Simulation using Virtual Commissio...

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IEEE/SICE International Symposium on System Integration

作者： Darius Deubert Denis Pfeifer Christian Scheifele Jörg Fehr Alexander Verl Bosch Rexroth AG 97816 Lohr am Main Germany and Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany Denis Pfeifer is with ISG Industrielle Steuerungstechnik GmbH 70563 Stuttgart and Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart Germany ISG Industrielle Steuerungstechnik GmbH Stuttgart Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart Germany Alexander Verl is with Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331531614

ISBN: (纸本)9798331531621

关键词： Energy consumption Automation Accuracy Service robots System integration Manufacturing systems

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Human-centric assembly in smart factories

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CIRP Annals 2025年

作者： Wang, Lihui Gao, Robert X. Krüger, Jörg Váncza, József Department of Production Engineering KTH Royal Institute of Technology Stockholm Sweden Department of Mechanical and Aerospace Engineering Case Western Reserve University Cleveland United States Institute for Machine Tools and Factory Management Technical University Berlin Germany Laboratory of Engineering and Management Intelligence Institute for Computer Science and Control Hungary

Assembly in future smart factories needs to address three challenges, including human centricity, sustainability, and resilience. Conventional approaches for automation in assembly have reached a bottleneck in terms of operation automomy, leaving various tasks to continued manual labour by human operators. To ease the burden on humans both physically and intellectually, human-centric assembly enhanced by augmented robots, cognitive systems, mixed reality and collaborative intelligence, assisted by thought-driven brain robotic controls, provides a promising solution. Within the context, this keynote provides an in-depth analysis of the state of human-centric assembly and identifies potentially fruitful research directions in future smart factories. © 2025 The Author(s)

关键词： Assembly Human-centricity Robot

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Automatic preload adjustment for ball screw drives by means of a spring-loaded mechanism

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CIRP Annals 2025年

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

Preloaded ball screw drives are widely used in high-precision linear motion applications, particularly in machine tool feed drives. To compensate for the loss of preload due to wear over the service life and to maintain typical operational characteristics such as zero backlash and high rigidity, ball screws are usually preloaded to high values. However, this results in increased wear and friction, with a consequent increase in temperature. To address these issues, this paper introduces a novel double nut design for ball screws, featuring a passive preload adjustment mechanism, enabling reduced preload levels while enhancing operating characteristics and operational service life.

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Process concatenation to reduce thermal changes in machine tools

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International Journal of Mechatronics and Manufacturing Systems 2022年第2-3期15卷 167-184页

作者： Wenkler, E. Selch, M. Hellmich, A. Ihlenfeldt, S. Institute for Machine Tools and Control Engineering Technische Universität Dresden Dresden01062 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01069 Germany

Thermal effects in machine tools are responsible for a significant amount of produced scrap. Therefore, various approaches have been investigated and applied on machine tools to reduce thermal changes during manufacturing. Most of them target the machine tool and its operational state and can therefore just react to the thermal changes caused by the process. This paper shows how thermal changes can be reduced already in the manufacturing planning stage. With the use of a virtual numerical control (VNC) and loss models, power losses can be estimated, enabling the concatenation of processes to achieve minimal jumps in power loss from one process to another. Copyright © Inderscience Enterprises Ltd.

关键词： Energy efficiency

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Chatter prediction for uncertain parameters

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Advances in Manufacturing 2018年第3期6卷 319-333页

作者： Michael Loser Andreas Otto Steffen Ihlenfeidt Günter Radons Institute of Machine Tools and Control Engineering TU Dresden 01069 Dresden Germany Institute of Physics Chemnitz University of Technology09107 Chemnitz Germany

The occurrence of chatter in milling processeswas investigated in this study. The prediction of the sta-bility lobes of metal cutting processes requires a model ofthe cutting force and a model of the dynamic machine toolbehavior. Parameter uncertainties in the models may leadto significant differences between the predicted and mea-sured stability behavior. One approach towards robuststability consists of running a large number of simulationswith a random sample of uncertain parameters and deter-mining the confidence levels for the chatter vibrations,which is a time-consuming task. In this paper, an efficientimplementation of the multi frequency solution and theconstruction of an approximate solution is presented. Theapproximate solution requires the explicit calculation of themulti frequency solution only at a few parameter points,and the approximation error can be kept small. This studyfound that the calculation of the robust stability lobe dia-gram, which is based on the approximate solution, is sig-nificantly more efficient than an explicit calculation at allrandom parameter points. The numerically determinedrobust stability diagrams were in good agreement with theexperimentally determined stability lobes.

关键词： Milling Chatter Uncertainties Vibration Stability

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ADAPTRONIC PRECISION POSITIONING TECHNOLOGY

ADAPTRONIC PRECISION POSITIONING TECHNOLOGY

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20th Reliability, Stress Analysis, and Failure Prevention Conference

作者： Pahlke, Achim Rosen, Simon Kaestner, Markus Moehring, Hans-Christian Reithmeier, Eduard Denkena, Berend Institute of Measurement and Automatic Control Hannover Germany Institute of Production Engineering and Machine Tools Hannover Germany

ISBN: (纸本)9780791849002

The adaptronic precision positioning technology is applied to the fitting of rotation-symmetric components such as gearwheels in a hard turning process in order to compensate eccentricity. Distorted gearwheels, showing e.g. a significant quench distortion, cause a malposition in the chuck during clamping. This malposition leads to low quality workpieces or scrap in the hard turning process. To compensate the malposition of the workpieces, a new technology for precision positioning within the rotating chuck is being researched. In the introduction, the motivation of the preceding research project "Allowance-oriented precision positioning" and the framework of the adaptronic precision positioning technology are summarized. Next part is the description of the system's components, beginning with the principles and the redesign of the mechatronic chuck. Completing the adaptronic precision positioning technology, the optical metrology, the data processing and automation aspects are shown in the following part. Afterwards, a short summary concludes this paper.

关键词： Clearances (engineering) Rotation Metrology Turning Fittings

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Interoperable Digital Product Passports: An Event-Based Approach to Aggregate Production Data to Improve Sustainability and Transparency in the Manufacturing Industry

Interoperable Digital Product Passports: An Event-Based Appr...

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2024 IEEE/SICE International Symposium on System Integration, SII 2024

作者： Ajdinović, Samed Strljic, Matthias Lechler, Armin Riedel, Oliver Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Germany

ISBN: (纸本)9798350312072

The manufacturing industry is increasingly focused on sustainability, requiring greater product transparency to meet sustainability targets. Digital Product Passports (DPPs) have emerged as a potential solution to improve recyclability and inform consumer purchasing decisions. However, there is a lack of methodology and digital representation for building DPPs, which hinders data linkage and sharing. In this paper, we propose an approach based on standardised data models and event sourcing to aggregate production data, using energy consumption as an example. We present a concept that captures and stores process information using event sourcing in Asset Administration Shells (AAS), and evaluate its feasibility through a manufacturing demonstrator. The results show that event-based aggregation facilitates the creation of DPPs, allowing different actors in the value chain to participate in an interoperable way. By leveraging a standardised and interoperable common data space, this approach improves product transparency, promotes recyclability and enables informed consumer choice in line with sustainability goals. © 2024 IEEE.

关键词： Transparency

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