Highly integrated hydraulic active feed unit for micro manufacturing with favorable ratio of build and work space

目前用于微加工的机床是用已知的运动学和测试过的部件组装的。因此，与工件相比，它们具有不利的构建空间，高能耗和大干涉轮廓，降低了工件的复杂性。因此，优先研究计划SPP 1476的目的是开发适用于新衍生部件的机床或机床链。在第一个资助期内，生产科学研究所开发了一种小型化，功能高度集成的液压进给单元。该进给单元将高阻尼静压导轨与具有高力密度的液压线性致动器相结合。通过这种设置，液压流体被多功能地用于推进、引导和温度控制，并且能够实现紧凑的设计。在第二个赠款期，其目标是分别将开发的模块联合收割机重新联合收割机到机床或机床链。在这样做的过程中，开发的进料单元面临着新的要求：在模块到机器的组合中，模块本身的不准确性以及组合之外的不准确性都必须得到补偿。这些不准确性在刀具中心点处累积成大的误差。除了误差补偿外，还需要一个特殊的启动程序和进给单元与机床的快速控制集成。因此，第一个授权期的液压进给单元应得到增强，并因此能够用于小型工件的小型机床的组合和重组。第一个授权期的带恒定节流阀的静压导轨不能补偿误差。但它基本上能够补偿内部误差、组合和重组之外的误差以及其他模块的误差。因此，必须通过主动控制油门来增强它。应在进料装置中实施主动控制节流阀。在此基础上，对主动静液制导系统的内部误差、组合重组后的误差以及其它模块的误差进行五自由度补偿，除补偿误差外，还要求组合重组后的快速启动程序。因此，微控制器将被实现到馈送单元中。该微控制器能够控制进料单元以及主控制和其他模块所需的数据存储和交换。该数据包括模块的特性以及其误差。此外，仿真模型应能够确定和优化控制器以及有源馈电单元的补偿参数。

Current machine tools for micromachining are assembled with known kinematics and tested components. For this reason they feature unfavorable build spaces in comparison to the workpieces, high energy consumptions and large interfering contours reducing the complexity of the workpiece. Therefore the aim of the research priority program SPP 1476 is to develop adapted machine tools or machine tool chains out of newly derived components.Within the first grant period a miniaturized, functional highly integrated hydraulic feed unit was developed at the Institute of Production Science. This feed unit combines a high damping hydrostatic guideway with a hydraulic linear actuator featuring high force density. With this set up the hydraulic fluid is used multifunctional for propulsion, guidance and temperature control and enables a compact design.In the second grant period it is targeted to combine respectively recombine the developed modules to machine tools or machine tool chains. In so doing the developed feed unit faces new requirements: In combination respectively recombination of modules to machines, the inaccuracies of the modules itself, but also out of the combination have to be compensated. These inaccuracies add up to a large error at the tool-center-point. Besides the error compensation an ad hoc start-up procedure and a fast control integration of the feed unit into the machine is required.Therefore the hydraulic feed unit of the first grant period shall be enhanced and enabled consequently for the combination and recombination of small machine tools for small workpieces.The hydrostatic guideway with constant throttles of the first grant period cannot compensate errors. However it is basically able to compensate internal errors, errors out of the combination and recombination as well as errors of other modules. Therefore it has to be enhanced with actively controlled throttles. Actively controlled throttles shall be implemented into the feed unit. With the help of this, active hydrostatic guidance system, internal errors, errors out of the combination and recombination as well as errors of other modules shall be compensated in five degrees of freedom.Besides the error compensation a fast an ad hoc start-up procedure after the combination and recombination is required. Therefore a microcontroller shall be implemented into the feed unit. This microcontroller enables the control of the feed unit and the storage and exchange of data, required for the main control as well as the other modules. This data consists out of the characteristics of the modules as well as its errors. Besides a simulation model shall enable the determination and optimization of the controller as well as the compensation parameters of the active feed unit.