Further development and implementation of a model-based, integratable multi-sensor system for automatic and process parallel determination and compensation of the volumetric error at the functional point (AutoKomp II)

随着技术的不断发展，生产技术朝着更高效的部件制造方向发展的趋势，这些部件具有越来越复杂的几何形状和不断缩小的公差。机床的定位精度对零件质量至关重要。机床运动与功能点处的标称运动的任何偏差（体积误差）都会传递到工件上并导致形状偏差。用于在不进行成本密集的设计改变或机械设置的情况下提高精度的现有技术工业方法是机床的校准，即测量机器误差，随后进行基于控制的补偿。由于机床的运动偏差随工艺、温度、负载和磨损而变化，静态补偿在短时间内（极端情况下几个小时）失效。尽管在工业中建立了校准的定期重复，但是由于运动偏差的高度可变性，它们是不够的，并且同时导致高成本。此外，在研究和工业中有许多方法来补偿个体几何误差的可变性。然而，对于所有相关的静态和弹性效应的实际应用，还没有一个整体模型。为了最大限度地提高校准的经济效益，避免昂贵和能源密集型空调，时间离散校准和机器状态的过程并行记录以及不同的建模方法应有效地结合起来。本项目第二阶段的目标是进一步开发和实施一个基于模型的、可集成的多传感器系统，用于功能点上的体积误差的自动和过程并行确定和补偿。基于在第一阶段开发和验证的用于线性轴内几何误差的过程并行检测的传感器设计，整个试验机将配备适当的传感器。此外，还将使用更多的传感器来记录机器和环境条件，例如结构部件的变形和温度分布。体积误差的直接测量将作为时间离散输入添加，用于整个模型的设置、调整和验证，因此必须最大化时间间隔。然后，该多传感器系统为混合整体模型方法提供数据，该方法一方面考虑了现有的和工业上建立的方法，但也试图将现代白盒和黑盒建模的优点联合收割机结合起来。该项目将在测试机器上进行一年的测试和验证，然后将其转移到其他机器类型并在第三阶段投入生产运行。

The trend in production technology towards more efficient component manufacturing with increasingly complex geometries and shrinking tolerances is unbroken due to the advancing technological development. The positioning accuracy of the machine tool is essential for component quality. Any deviation of the machine movement from the nominal movement at the functional point (volumetric error) is transferred to the workpiece and results in shape deviations. A state of the art industrial method for increasing precision without cost-intensive design changes or mechanical settings is the calibration of the machine tool, i.e. measuring the machine errors, with subsequent control-based compensation. Since the movement deviations of the machine tool vary depending on the process, temperature, load and wear, static compensations lose their validity within short periods of time (in extreme cases a few hours). Although regular repetitions of the calibration are established in industry, they are insufficient due to the high variability of the motion deviation and at the same time cause high costs. In addition, there are numerous methods in research and industry to compensate for the variability of individual geometric errors. Still, there is no overall model for the practical application to all relevant static and elastic effects. To maximize the economic benefit of calibrations and to avoid costly and energy-intensive air conditioning, time-discrete calibrations and the process-parallel recording of machine states as well as the different modelling approaches should effectively combined. The aim of the second phase of the overall project applied for here is the further development and implementation of a model-based, integratable multi-sensor system for automatic and process parallel determination and compensation of the volumetric error at the functional point. Based on the sensor design for the process-parallel detection of geometric errors within a linear axis, which was developed and validated in phase one, the entire test machine is to be equipped with appropriate sensors. In addition, further sensors will be used to record machine and environmental conditions, such as the deformation of structural components and temperature distribution. Direct measurements of the volumetric error will be added as time-discrete inputs for the setup, adjustment and validation of an overall model, whereby the time intervals for this must be maximized. This multi-sensor system then provides data for a hybrid overall model approach, which on the one hand takes into account existing and industrially established methods, but also attempts to combine the advantages of modern white-box and black-box modelling. The project will be tested and validated on a test machine for one year before it is to be transferred to other machine types and into productive operation in phase three.