Multidisziplinäre Simulation und Optimierung mechatronischer Systeme am Beispiel einer Werkzeugmaschine

In order to cope with the global challenges in the area of production technology, manufacturers of machine tools are always required to develop products which feature a higher level of innovation compared to competitors. Key words such as higher speed, precision, dynamic and lightness characterize the trends in the field of production technology and rule the vocabulary of both development and marketing. Facing an environment of permanently growing power densities and precision requirements combined with the conversion of larger energy quantities in shorter periods of time, the impact of the transient thermal behaviour on the accuracy of modern machine tools has reached a significant level. As a consequence, the thermal behaviour has to be analysed just as well as kinematic, static and dynamic aspects. Including those aspects in appropriate models by following a multidisciplinary approach combining CAx-tools from different areas therefore is a vital prerequisite to gain important information to be used in the development process of a new machine tool [1]. In this paper, the integrational use of CAx-Tools for the optimization of a lightweight robot is demonstrated [2]. In addition, a simulation environment to investigate the thermal influence resulting from the movement of the NC-axes of a machine tool is presented. In both cases, the aim of the simulation methodology is to identify and analyse the heat input by using real NC-programs already at an early stage of the design process by means of computer models. Subsequently, the simulation environment is used to calculate the resulting deformations and displacements of the machine components. The results gained from the simulation can provide valuable information to be considered when designing machine tools, such as for the correct location of measurement systems, the sensor technology as well as for the development of compensation strategies. Currently, the simulation methodology is being validated by applying it to a 5-axes universal milling machine. The methodology used hereby is characterized by a multidisciplinary approach and the simulation of mechatronic systems by combining mechatronic, electric, thermal, fluid-mechanical and control engineering components.