C02: Modelling and design of systems for active control of temperature distribution in frame subassemblies

The object of research of subproject C02 is the characterisation, realisation and control of compensation networks for temporal and spatial redistribution of heat in machine tools. In addition to the developed thermal storage and switch based components, controllable heat pipe systems are investigated. Considering deterministic and random loads, a corresponding network is designed and tested with regards to the thermal error reduction. Based on the numerical and experimental findings, design and construction criteria are provided in order to incorporate the compensation components within the virtual design of machine tools.

C03: Concept to determine thermo-elastic deformations by directly measuring local shifts using structurally integrated sensors

The main objective of subproject C03 is the metrological detection of thermo-elastic deformations during machining in three-axis machine tools by means of a retrofit sensor system. The overall approach includes the mechanical deformation model, the control integration methodology, and the sensor placement optimization methodology. The reliability of the correction concept depends on these components and will be examined in phase 3. After the concept was confirmed under real conditions in integration objects in the second phase, the applicability of the overall approach will be validated on practice-relevant use cases on demonstrators.

C04: Modelling and optimisation of power losses in electrical drives and their thermal coupling with machine tools

C04 develops a targeted loss control of the drive motors to be used as heat managers to influence the heat flows into the machine structure, without thermal overloads as well as impermissible speed or torque fluctuations occur. In addition, a multiphysics motor simulation in combination with a state estimator allows the early detection of parameter deviations and errors. Furthermore, in cooperation with C02, the effectiveness of thermal absorbers based on phase change materials to stabilize the heat flows in electric motors is universally predicted and experimentally confirmed. Finally, the improvement potential of new additive manufacturing technologies and new materials for the internal thermal resistances of the motors is estimated.

C05: Model based method for the evaluation of the solution variants in design and realisation in particular under thermal-energetic, qualitative and economic aspects

The aim of TP C05 is to assess the approaches of the subprojects with a thermo-energetic, qualitative and economic point of view. Therefore a valuation model including the metric, which brings together the evaluation criteria for benefit and effort, were developed. The comparability required for the evaluation was established with a standardized description provided by the self-developed DOCASYS documentation and assistance system. In phase 3, adequate load cases for the experimental and simulative investigations will be developed for realistic scenarios. In addition, methods for the selection of suitable approaches (e.g. by applying fuzzy technologies) and their combinability will be developed, which will be implemented in DOCASYS, and the effectiveness of the approaches over time will be investigated.

C06: Measurement of behavior and operating state relevant values along the thermal effect-chain for analysis, evaluation, simulation and correction on the example of a specific test bed machine.

The subproject C06 deals with the metrological analyses along the thermal effect chain on the example of a specific test bed machine „MAX“. It was possible to create a measurement model, using a self-configured optical measurement system and the self-developed program „Photogrammetric Toolkit“. This enables the simultaneous recording of deformation and displacement states of the machine. The experiences made in second phase will be used to better the photogrammetric measurement by referring to the environmental effects (increase of accuracy) and to increase the stability of the measurement by using further sensors (interferometer, thermocouples etc.). The information from this sensor data fusion will be bundled and evaluated in the measurement model in order to record machine-related parameter fluctuations. In this way, the calculation of the correction approaches of the other TPs can be verified metrologically.

Service project Z02: Demonstration

In phase 3, the correction and compensation solutions on demonstrator machines will be verified experimentally.  Z02 supports the subprojects of different locations in the development, execution and evaluation of the tests on the demonstrator machines.

This includes, for example, the modification of the demonstrator machines or programming work as well as the time coordination of the test execution, consulting in the selection of the measurement technology and participation in the set-up of the test arrangements.