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/TR96研究的挑战来自于试图满足降低能耗和提高加工精度和生产率这两个相互冲突的目标。所采用的解决方案基于以下措施：在热瞬变环境条件下以及在以单件和小批量生产为特征的操作条件下，即使在功率损耗增加的情况下也能保证工艺精度，而无需额外的能量措施。CRC/TR96的科学家们正在研究和开发有效的热弹性机器行为校正和补偿解决方案，这将使在未来的节能生产条件下进行精密加工成为可能。以下子目标由此产生：1)开发用于综合计算热弹性变形和引起它们的热通量的建模基础，以及用于绘制由于相对运动而引起的结构变异性的映射和最小化计算时间；2)实现当前数据图像作为热弹性功能链的数字表示。这包括模型数据和参数，并提供了循环更新的可能性。3)记录热源和热汇对机床热行为的影响以及对时间行为的描述。通过参数识别程序跟踪局部和时间波动的参数，作为校正和补偿方法设计和运行的先决条件，4)开发用于检测机床特定结构区域中的热弹性故障的基本计量方法，并将其用于校正和补偿解决方案，5)在考虑伴随过程的数据分析的情况下，开发和实施控制综合校正热弹性故障的解决方案。6)开发和整合设计和材料性能支持的方法，用于通过稳定温度场以及减少和均化在承载结构区域中输入的热能来补偿热弹性效应，7)对SFB/TR96中制定的措施进行技术经济评估，评估这些措施对产品质量、批量性能、能源消耗和成本的影响。在第三阶段(演示阶段)，研究工作涉及整个机器。在简单局部模型和整体模型研究成果的基础上，将校正和补偿方法转化为实际运行条件下整机的应用。由于大量的不确定性和参数波动，这导致了新的科学挑战。必须进一步开发这些模型，并开发新的解决方案，用于在线识别等可变运行条件的控制。

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.