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MACH21Mach21 in EMO 2003
Mach21 in EMO 200321-28/10/2003
Multipurpose and cross-sectorial modernisation of manufacturing
processes through parallel kinematics
MACH21Mach21 in EMO 2003
Requirements for the new machines:
– Customer and process focused solutions.
– High feed rates (machining and traverse movements).
– High accelerations.
– High stiffness.
– Good dynamic behaviour (high Jerk and kv values).
– Low cost (high productivity).
– Reliability.
– Process specific precision.
…¿is this possible with conventional solutions?
Not in a sustainable way. Need for breakthrough.
JUSTIFICATIONJUSTIFICATION
MACH21Mach21 in EMO 2003
MACH21: an answer to the European challenges:
– modernise the manufacturing processes of the industry .
– standardise as much as possible both the mechanical and electronic (numeric control, measuring devices) components
– reconfiguration and reuse of manufacturing systems.
– minimising the material consumption
– Contribute to speeding up industry's adjustment to structural changes’
– safety in the machinery.
– Educational aspects
JUSTIFICATION: the European perspectiveJUSTIFICATION: the European perspective
MACH21Mach21 in EMO 2003
What is a parallel kinematics machine (PKM)?
Traditional (serial) machines: each axis or carriage carries the subsequent axis to provide the desired tool movements
Parallel kinematic machines (PKMs): the tool movements are achieved via coordinated traslations of several axis arranged in parallel. No longer a carriage transports another one.
MACH21Mach21 in EMO 2003
Serial machineSerial machine PKM machinePKM machine
MACH21Mach21 in EMO 2003
MACH21: a cross-sectorial technological platform
Aeronautics
Automotive sector with assembly processes,
Textile sector, for
Moulds and dies,
handling in automation processes
Other manufacturing sectors:
MACH21Mach21 in EMO 2003
GERMANY
ITALY
PORTUGAL
SPAIN
• WZL• INA• IWU• Karl Mayer• ISW• Lernstatt
• Comau• Gamesa• Anayak• Fatronik
• Arjal
FRANCE• Lirmm
MACH21Mach21 in EMO 2003
MACH21Mach21 in EMO 2003
MACH21 objectives
• The project MACH21 has meant an holistic or overall approach to PKMs in order to try to solve or minimize the most important generic problems that affected this technology at the beginning of the project, through the whole life cycle.
• This way the project bets for a modernisation of the production means and brings nearer the implementation phase of the parallel kinematics production technology in the industrial companies shop floors by improving the PKMs performances in the areas of accuracy, dynamics and flexibility.
MACH21Mach21 in EMO 2003
COMPONENTS-Joints & Struts
• Improved in behaviour telescopic struts and drives
• Optimized joints for a wide range of processes with different characteristics and problematic
MACH21Mach21 in EMO 2003
PKM design assistance tools
Software programs and digital models for aiding the designers to assess and simulate the static and dynamic capabilities of a particular PKM architecture in a preliminary conceptual design stage
MACH21Mach21 in EMO 2003
Static and dynamic accuracy improvements
Drives: A1, A2
A2
forcelessmeasurementstructur
passive guidelines: P1 ... P4
P4
P3
P2
P1A1 rotaryencoder
Rz
New calibration methods and devices obtained for enhancing machine static accuracy
20
20
Methods to monitore and compensate static errors (gravity, thermal) not corrected by analytical model-based calibrations
Control strategies and algorithms for improving the dynamic accuracy
CartesianTrajectoryGeneration
C Robot
[Vector ofTOOL
positions]nx1
[EXTENDED positions](n+r)x1
[EXTENDED errors](n+r)x1
[Vector of EXTENDED
sensors measurements](n+r)x1
[EXTENDED to JOINT transformationmatrix](n)x(p+r)
[JOINT controller]
RKM
IKM
[Vector ofMODIFIED errors](n)x1
+-
TEJ
FKM (Robot User)
[Vector ofREDUNDANT
positions]rx1
[JOINT positions]nx1
Drives: A1, A2
A2
forcelessmeasurement
structur
passive guidelines: P1 ... P4
P4
P3
P2
P1A1
rotaryencoder
R
z
d x
d x
d x
K p
K v ) ( ~ x A
f d computation
ROBOT
H ~
t m J
) ( q h x
+ +
+
+
+
+ - -
f n
f d
q
dt dq /
w
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes
New PK designs ending in technology demonstrator prototypes for the following industrial processes and sectors:
– High dynamic handling prototype (automotive sector)– 5 axes horizontal milling prototype (aeronautic sector)– 5 axes vertical milling prototype (mould and die sector)– “Heavy Tow” fibers layer prototype (textile sector)– Thin panels assembly in skeletal structures of ribs and spars (virtual
prototype, aeronautic sector)
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes (I)
4 DOF high dynamic handling prototype (automotive sector)
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes (II)
• 5 axes horizontal milling prototype (aeronautic sector)
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes (III)
5 axes vertical milling prototype (mould and die sector)
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes (IV)
“Heavy Tow” fibres layer prototype (textile sector)
MACH21Mach21 in EMO 2003
Demonstrators/Prototypes (V)
• Thin panels assembly in skeletal structures of ribs and spars (virtual prototype, aeronautic sector)
MACH21Mach21 in EMO 2003
MACH21: the snowball effect
• EMO2003: the fist time in history for a specific classification of PKM machines.
• 16 first-class manufacturers offering market ready PKM machines at the EMO2003
• 4 components suppliers for PKM machines at the EMO2003
• 14 of these companies have relation with MACH21 or their partners.