TRR 96: Thermo-Energetic Design of Machine Tools - A Systemic Approach to Solve the Conflict between Power Efficiency, Accuracy and Productivity Demonstrated at the Example of Machining Production

CRC/TR 96研究的挑战来自于试图满足减少能耗和提高加工精度和生产率这两个相互冲突的目标。所追求的解决方案方法是基于这样的措施，即在热瞬态环境条件下以及在以单独和小批量生产为特征的操作条件下，尽管功率损耗增加，但仍可以保证过程精度，而无需额外的能量措施。CRC/TR 96的科学家们正在研究和开发针对热弹性机床行为的有效校正和补偿解决方案，这将使未来节能生产条件下的精密加工成为可能。以下子目标由此衍生：1）为热弹性变形和引起热弹性变形的热通量的综合计算能力，以及为由于相对运动和最小化计算时间而引起的结构变化的映射，开发建模基础，2）将当前数据图像实现为热弹性函数链的数字表示。这包括模型数据以及参数，并提供了周期性更新的可能性。3）记录热源和散热器对机床热行为的影响以及时间行为的描述。通过参数识别过程跟踪局部和时间波动参数，作为校正和补偿方法的设计和操作的先决条件，4）开发用于检测机床的特定结构区域中的热弹性故障的基本热弹性方法及其用于校正和补偿解决方案的用途，5）在考虑过程伴随数据分析的情况下，开发和实施热弹性故障的控制集成校正解决方案。6）开发和集成热弹性故障补偿的设计和材料特性支持方法。通过稳定温度场和减少并均匀化在承载结构区域内的热能输入来实现弹性效应。7）对SFB/TR 96中制定的措施进行技术经济评估，评估其对产品质量、体积性能、能耗和成本的影响。在第3阶段（演示阶段），研究工作涉及整个机器。在简单的局部模型和整体模型研究的基础上，将修正和补偿方法推广到真实的运行条件下的整机应用中。这导致了新的科学挑战，由于大量的不确定性和参数波动。这些模型必须进一步开发，并且必须开发用于控制可变操作条件的新解决方案，例如在线识别。

The challenge of research in the CRC/TR 96 derives from the attempt to satisfy the conflicting goals of reducing energy consumption and increasing accuracy and productivity in machining. The solution approach pursued is based on measures that make it possible to guarantee process accuracy despite increasing power losses without additional energetic measures under thermal transient environmental conditions and under operating conditions characterized by individual and small series production. The scientists of the CRC/TR 96 are researching and developing effective correction and compensation solutions for the thermo-elastic machine behavior, which will enable precision machining under the future conditions of energy-efficient production.The following subgoals are derived from this:1) Development of modeling fundamentals for a comprehensive calculation capability of thermo-elastic deformations and the heat fluxes causing them, as well as for the mapping of structural variability due to relative movements and minimization of calculation time,2) Implementation of a current data image as a digital representation of the thermo-elastic functional chain. This includes model data as well as parameters and provides for the possibility of a cyclic update.3) Recording of the effects of heat sources and sinks on the thermal behaviour of machine tools as well as the description of the temporal behaviour. Tracking of locally and temporally fluctuating parameters by means of parameter identification procedures as a prerequisite for the design and operation of correction and compensation approaches,4) Development of basic metrological approaches for the detecting of thermo-elastic failures in specified structural areas of machine tools and their use for correction and compensation solutions,5) Development and implementation of solutions for the control-integrated correction of thermo-elastic failures under consideration of process-accompanying data analysis.6) Development and integration of design and material property-supported approaches for the compensation of thermo-elastic effects by stabilisation of the temperature field and reduction and homogenisation of the heat energy input in the area of load-bearing structures, 7) Technical-economic evaluation of the measures developed in the SFB/TR 96 with regard to their impact on product quality, volume performance, energy consumption and costs.In phase 3 (demonstration phase), the research work relates to the entire machine. On the basis of the research results on simple partial and overall models, correction and compensation approaches are transferred to the application for the entire machine under the conditions of real operation. This leads to new scientific challenges due to a multitude of uncertainties and parameter fluctuations. The models have to be further developed and new solutions for the control of variable operating conditions such as online identification have to be developed.