C. Brecher’s research while affiliated with Fraunhofer Institute for Production Technology IPT and other places

During machining, process forces cause form deviations on the workpiece depending on the interacting stiffnesses of all components involved. In order to avoid tolerance violations, it must be ensured that the resulting deflection of tool and workpiece are within the tolerance limit. At the same time, process parameters must be selected in such a way that a cost-efficient and productive production is possible. Stiffness can be determined experimentally by applying a specific force and measuring the resulting deformation. Due to the large variety of tools and tool holders as well as their combinations, it is generally too expensive to determine the stiffness in this way. During quality control, the workpiece geometry is measured, for example, with coordinate measuring Machines (CMM), so that resulting dimensional and form deviations can be determined. Furthermore, there exist approaches to predicting process forces based on machine internal data such as motor currents. In this paper, an approach is presented that enables a determination of the resulting system stiffness at the TCP based on machine-internal and quality data. During the milling process, machine internal data is recorded and a dexel-based material removal simulation (MRS) is performed. Therefore, the estimated force vector is calculated for each dexel. After the simulation, the virtual part is compared with the real part measured by a CMM to determine the deviation vector. By solving a linear equation system, the resulting stiffness is calculated. To reduce the influence of other effects, they are modeled in the MRS or usually reduced so that they are negligible.

Various sensors as well as the numeric control serve as sources for the acquisition of process data in operating machine tools. Since the manufacturing industry acknowledges the value immanent to the data, numerous approaches to analyze and exploit large amounts of data have been developed. Generating comparable data sets represents a general challenge when collecting data in real production environments. Multiple external interferences, such as interventions by the operator, alter the manufacturing process and the data set. In order to ensure the transferability of results, a standardized preprocessing and the comparability of data sets, such interferences need to be eliminated by a synchronization algorithm. In this paper, a novel approach is presented, which allows for a synchronization of numeric control process data sets considering multivariate raw data. The approach is able to align data sets of different lengths considering local process modifications. Reliably synchronizing data sets, the presented algorithm aims to support data preprocessing in manufacturing environments and, thus, facilitates the application of data-driven solutions for production optimization.

Conventional industrial robots (IR) represent a cost-effective machining alternative for large components. However, due to the serial kinematics and the resulting high tool deflections, they usually lack precision. Model-based simulation and control methods are used to increase the accuracy of IR regarding both planning and the process itself. The majority of the applied models include the compliances of the gears and bearings but neglect the deformations of the manipulator bodies. This paper introduces an approach to directly measure and evaluate the deformation of robot bodies in the presence of process forces. The measurement setup contains multiple Integral Deformation Sensors (IDS), which provide the change of length due to deformations of the respective body. Subsequently, the measurements are fed to a beam model (BM), which calculates the body’s 3D Cartesian deflections. The presented approach is validated by static tensile tests on a conventional six-degree-of-freedom (DOF) robot manipulator.

Due to their low rigidity compared to machine tools, industrial robots (IRs) are less suitable for dynamic processes such as machining. In order to benefit from the flexibility and large workspace of IRs for e.g. machining of large workpieces, a model-based feedforward control can be used to compensate the deviations of the tool center point. This control algorithm does not require additional components but a dynamics model of the IR, incorporating effects such as mass inertia and friction. This paper focuses on friction modeling of robotic drive trains comparing analytical, e.g. the LuGre model, and data-driven models, e.g. Long Short-Term Memory networks. The models are parametrized and trained using data from the first axis of a 6-degree-of-freedom IR and evaluated regarding their ability to model dynamic nonlinear friction effects like stick-slip. This serves as a basis for structured learning of robot dynamics by combining analytical and data-driven models.

Im Rahmen des alljährlich stattfindenden Treffens von wissenschaftlichen Mitarbeitern der Institute des Produktionstechnischen Zentrums (PTZ) Berlin, des Instituts für Steuerungstechnik der Werkzeugmaschinen und Fertigungseinrichtungen (ISW) der Universität Stuttgart und des Werkzeugmaschinenlabors (WZL) der RWTH Aachen wurde am 05. und 06. Oktober 2022 der aktuelle Stand der Forschung zum Thema „Algorithmik und KI für moderne Roboterapplikationen – ein Überblick“ in Aachen diskutiert. Der hier vorliegende Band enthält die Ergebnisse der abgehaltenen Veranstaltung. Inhalt Algorithmik und KI für moderne Roboterapplikationen – ein Überblick III FPGA-basierte Signalverarbeitung kapazitiver Sensorflächen für Industrie- und Servicerobotikanwendungen 1 1 Motivation..............................2 2 Ansatz ..................4 2.1 Hardware-Software-Architektur ..................4 2.1.1 Datenhandler......................5 2.1.2 Hardwarealgorithmusblock..............5 2.1.3 Hardwarekonfiguration.............5 2.1.4 Datenkommunikation ................6 2.1.5 Validierung der H/S-Architektur............6 2.2 Kapazitätsausleseelektronik ..............7 2.2.1 Funktionsweise ........

Im Rahmen des alljährlich stattfindenden Treffens von wissenschaftlichen Mitarbeitern der Institute des Produktionstechnischen Zentrums (PTZ) Berlin, des Instituts für Steuerungstechnik der Werkzeugmaschinen und Fertigungseinrichtungen (ISW) der Universität Stuttgart und des Werkzeugmaschinenlabors (WZL) der RWTH Aachen wurde am 05. und 06. Oktober 2022 der aktuelle Stand der Forschung zum Thema „Algorithmik und KI für moderne Roboterapplikationen – ein Überblick“ in Aachen diskutiert. Der hier vorliegende Band enthält die Ergebnisse der abgehaltenen Veranstaltung. Inhalt Algorithmik und KI für moderne Roboterapplikationen – ein Überblick III FPGA-basierte Signalverarbeitung kapazitiver Sensorflächen für Industrie- und Servicerobotikanwendungen 1 1 Motivation..............................2 2 Ansatz ..................4 2.1 Hardware-Software-Architektur ..................4 2.1.1 Datenhandler......................5 2.1.2 Hardwarealgorithmusblock..............5 2.1.3 Hardwarekonfiguration.............5 2.1.4 Datenkommunikation ................6 2.1.5 Validierung der H/S-Architektur............6 2.2 Kapazitätsausleseelektronik ..............7 2.2.1 Funktionsweise ........

Foreword The International Conference on Gears in Garching near Munich, Germany, is an established platform for researchers on and manufacturers of gears and transmission systems. At the 10th issue of the conference in September of 2023, gear experts discussed the latest developments and research results from the powertrain industry and academia. Given the increasing challenges of climate change and its impacts, acting in compliance with the UN Sustainable Development Goals is mandatory for all engineers today. Gear engineers must consider these objectives in their research and development activities and provide solutions that meet the technical requirements and contribute to achieving the UN goals. Greenhouse gas (GHG) emission is a primary driver for climate change. Reducing GHG emissions should be an urgent action for the combat against climate change. Therefore, the research on efficiency is assigned a key role. Several contributions in this report discuss the possibilities for further improvement in efficiency from different points of view, like gear design or lubrication. Other subjects of the conferences are Responsible Consumption and Production. H...

Foreword The International Conference on Gears in Garching near Munich, Germany, is an established platform for researchers on and manufacturers of gears and transmission systems. At the 10th issue of the conference in September of 2023, gear experts discussed the latest developments and research results from the powertrain industry and academia. Given the increasing challenges of climate change and its impacts, acting in compliance with the UN Sustainable Development Goals is mandatory for all engineers today. Gear engineers must consider these objectives in their research and development activities and provide solutions that meet the technical requirements and contribute to achieving the UN goals. Greenhouse gas (GHG) emission is a primary driver for climate change. Reducing GHG emissions should be an urgent action for the combat against climate change. Therefore, the research on efficiency is assigned a key role. Several contributions in this report discuss the possibilities for further improvement in efficiency from different points of view, like gear design or lubrication. Other subjects of the conferences are Responsible Consumption and Production. H...

Im Rahmen des alljährlich stattfindenden Treffens von wissenschaftlichen Mitarbeitern der Institute des Produktionstechnischen Zentrums (PTZ) Berlin, des Instituts für Steuerungstechnik der Werkzeugmaschinen und Fertigungseinrichtungen (ISW) der Universität Stuttgart und des Werkzeugmaschinenlabors (WZL) der RWTH Aachen wurde am 05. und 06. Oktober 2022 der aktuelle Stand der Forschung zum Thema „Algorithmik und KI für moderne Roboterapplikationen – ein Überblick“ in Aachen diskutiert. Der hier vorliegende Band enthält die Ergebnisse der abgehaltenen Veranstaltung. Inhalt Algorithmik und KI für moderne Roboterapplikationen – ein Überblick III FPGA-basierte Signalverarbeitung kapazitiver Sensorflächen für Industrie- und Servicerobotikanwendungen 1 1 Motivation..............................2 2 Ansatz ..................4 2.1 Hardware-Software-Architektur ..................4 2.1.1 Datenhandler......................5 2.1.2 Hardwarealgorithmusblock..............5 2.1.3 Hardwarekonfiguration.............5 2.1.4 Datenkommunikation ................6 2.1.5 Validierung der H/S-Architektur............6 2.2 Kapazitätsausleseelektronik ..............7 2.2.1 Funktionsweise ........

Foreword The International Conference on Gears in Garching near Munich, Germany, is an established platform for researchers on and manufacturers of gears and transmission systems. At the 10th issue of the conference in September of 2023, gear experts discussed the latest developments and research results from the powertrain industry and academia. Given the increasing challenges of climate change and its impacts, acting in compliance with the UN Sustainable Development Goals is mandatory for all engineers today. Gear engineers must consider these objectives in their research and development activities and provide solutions that meet the technical requirements and contribute to achieving the UN goals. Greenhouse gas (GHG) emission is a primary driver for climate change. Reducing GHG emissions should be an urgent action for the combat against climate change. Therefore, the research on efficiency is assigned a key role. Several contributions in this report discuss the possibilities for further improvement in efficiency from different points of view, like gear design or lubrication. Other subjects of the conferences are Responsible Consumption and Production. H...