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Improved Machinery Performance using Active Control Technology

Objective


- SMART-Machine-Technology software to simulate 6 mechatronic systems, available in 3 laboratory test-rigs and 2 industrial test rig applications, and 1 case study
- application of the SMART-Machine-Technology on
- a rotating structure where different faults can be added and can be compensated by the SMART system technology
- a milling machine structure being capable to diagnose and to compensate by means of piezoactuators systems changes
- an adaptive squeeze film damper test rig being capable to alter the bearing properties to control different operating environments
- a high speed grinding spindle running in Active Magnetic Bearings which is capable to diagnose the process state and actively intervene on the process
- a design study of the application of piezoactuators for active vibration control to medium sized milling machine illustrating the technologies benefits and limitations.
Objectives and content
Mechatronic products enjoy their increasing significance
in the industrial world. The various integrated sensors
deliver on-line-information about system and process
condition. Actuators, controlled by microprocessors, can
be applied to influence the system behaviour. Realised
applications in industry are e.g. rotors in
turbomachinery and machine tool spindles, both supported
in magnetic bearings. There is a higher potential in
this mechatronic technology which can only be exhausted
using high sophisticated software tools for modelling,
diagnosis, prognosis and correction; tools that are not
available today. There are several opportunities to use
such a smart technology: advanced grinding processes
require shaft rotation speeds up to 120 000 rpm and online cutting-force corrections; a save and reliable
turbine operation without lubricants depends on available
controlling and correction tools, including rotordynamic
models; a large, precise milling machine needs selfadjusting features to increase accuracy and reduce time
and costs.
A new SMART-Machine-Technology will have an overall
system information not only due to monitoring systems but
also because of an entire structure and process model.
This enables an active adjustment and optimisation of
machine and process with respect to high performance
(accuracy, power density, etc.) and high reliability
(extended maintenance intervals, safety, etc.).
The proposed basic research project investigates
different areas:
modelling of entire mechatronic systems with respect to
process-, controller- and actuator/sensor-behaviour
development of model-based diagnosis/prognosis and
correction algorithms for mechatronic products (SMARTMachine-Technology)
design studies to realise the full potential of SMARTMachine-Technologies in industrial cases
The project focuses on the development of software tools,
the development of additional hardware is considered if
necessary. The three involved European universities will
develop this advanced technology. Two test rigs will
validate their methods and demonstrate the achieved
improvements. Three industrial partners define wide
spread requirements and check the systems feasibility.
The SMART-Machine-Technology will also be applicable to
other high-tech industries such as chemical industry,
power generation, and automotive production and aircraft
engines.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

UNIVERSITAET DARMSTADT/TU
Address
30,Petersenstrasse 30
64287 Darmstadt
Germany

Participants (5)

Eidgenössische Technische Hochschule - ETH Zürich
Switzerland
Address
101,Raemistrasse
8092 Zürich
IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDICINE
United Kingdom
Address
Exhibition Road
SW7 2BX London
MECOS TRAXLER AG
Switzerland
Address
36,Industriestrasse 26
8404 Winterthur
Mecanizaciones Aeronauticas SA
Spain
Address
26,Rérez Galdós
26509 Logroño - La Rioja
ROBERT BOSCH GMBH
Germany
Address
2,Robert-bosch-strasse 2
70442 Stuttgart