Qualification of function integrated feed units on the basis of compliant mechanisms in small machine tools for small work pieces

该项目旨在为小型模块化高精度机床非直观地开发基于柔顺机构的进给单元，并在基于软件的过程中实现它。柔顺机构具有运动精度高、无摩擦等优点，适合用于微细加工，柔顺机构的设计是一项复杂的工作。非常重要的方面是柔性铰链的位置和连接它们的刚性部件。此外，柔性铰链和连接刚性部件的几何形状对整个机构的静、动态性能有重要影响。基于结构优化的方法，如拓扑优化、几何优化等，可以快速、非直观地对柔顺机构进行造型，精确的柔顺机构建模对进一步的优化、分析和控制等研究具有重要意义。为了在数学轨迹优化和实时控制中使用，建立有效的数学模型是必不可少的。直接相关的是柔性铰链的精确近似。需要确定寄生运动和力学特性，以确保模型的高精度。在动力学模型的基础上，需要推导、分析和求解弹道优化问题的数学描述。数学研究的重点在于考虑机器所需的高精度和模块化的适当建模以及高效求解器的开发和实现。其目的是获得适应微制造要求的软件，该软件可以适应不同的进给单元。该软件应适用于耦合进料单元，并集成到整个开发过程的软件中。使用动态模型将推导出控制进给单元的方法。一个具有挑战性的要求是，即使存在诸如加工力之类的干扰，也要确保高精度的运动。另一项任务是确保进给单元能够快速连接，并准备好在组合机床中使用。这应通过根据机床配置构建和实施控制方法来实现。将进行实验研究，以量化进给单元的性能，并确保其在微制造中的适应性。

This project aims for a non-intuitive development of feed units based on compliant mechanisms for small modular high precision machine tools and its realization in a software-based process. High precision in motion and the absence of friction are the main advantages of compliant mechanisms qualifying them for the use in micro manufacturing.The design of compliant mechanisms turns out to be a complex task. Aspects of great importance are the position of flexure hinges and the stiff parts connecting them. Moreover, the geometry of flexure hinges and the connecting stiff parts are significant concerning the static and dynamic behavior of the entire mechanism. Methods based on structure optimization such as topology and geometry optimization shall be used to shape compliant mechanisms in a quick and non-intuitive way.Accurate modeling of compliant mechanisms is of essential importance for further investigations such as optimization, analysis and control. The derivation of efficient mathematical models is absolutely necessary for the use in mathematical trajectory optimization and real-time control. Directly related is the precise approximation of flexure hinges. Parasitic motion and mechanical properties need to be determined to ensure a high accuracy of the model. Based on the dynamic model, a mathematical description of the problem of trajectory optimization needs to be derived, analyzed and solved. The focus of mathematical research lies on an appropriate modeling considering the required high precision and modularity of the machine as well as the development and implementation of an efficient solver. The aim is to acquire software adjusted to the requirements of micro manufacturing which can be adapted for various feed units. This software shall be qualified for coupled feed units and integrated into the software of the whole process of development. A method of controlling the feed unit will be derived using the dynamical model. A challenging requirement is to ensure highly precise motion despite the presence of disturbances such as the forces of processing. A further task will be to assure the feed unit is quickly coupleable and ready for use in a modular machine tool. This shall be achieved by constructing and implementing control methods depending on the machine tool configuration. Experimental investigation will be carried out to quantify properties of feed units and to ensure their adaptability in micro manufacturing.