MACH21 Mach21 in EMO 2003 Mach21 in EMO 2003 21-28/10/2003 Multipurpose and cross-sectorial modernisation of manufacturing processes through parallel kinematics.

MACH21Mach21 in EMO 2003

Mach21 in EMO 200321-28/10/2003

Multipurpose and cross-sectorial modernisation of manufacturing

processes through parallel kinematics

MACH21Mach21 in EMO 2003

Requirements for the new machines:

– Customer and process focused solutions.

– High feed rates (machining and traverse movements).

– High accelerations.

– High stiffness.

– Good dynamic behaviour (high Jerk and kv values).

– Low cost (high productivity).

– Reliability.

– Process specific precision.

…¿is this possible with conventional solutions?

Not in a sustainable way. Need for breakthrough.

JUSTIFICATIONJUSTIFICATION

MACH21Mach21 in EMO 2003

MACH21: an answer to the European challenges:

– modernise the manufacturing processes of the industry .

– standardise as much as possible both the mechanical and electronic (numeric control, measuring devices) components

– reconfiguration and reuse of manufacturing systems.

– minimising the material consumption

– Contribute to speeding up industry's adjustment to structural changes’

– safety in the machinery.

– Educational aspects

JUSTIFICATION: the European perspectiveJUSTIFICATION: the European perspective

MACH21Mach21 in EMO 2003

What is a parallel kinematics machine (PKM)?

Traditional (serial) machines: each axis or carriage carries the subsequent axis to provide the desired tool movements

Parallel kinematic machines (PKMs): the tool movements are achieved via coordinated traslations of several axis arranged in parallel. No longer a carriage transports another one.

MACH21Mach21 in EMO 2003

Serial machineSerial machine PKM machinePKM machine

MACH21Mach21 in EMO 2003

MACH21: a cross-sectorial technological platform

Aeronautics

Automotive sector with assembly processes,

Textile sector, for

Moulds and dies,

handling in automation processes

Other manufacturing sectors:

MACH21Mach21 in EMO 2003

GERMANY

ITALY

PORTUGAL

SPAIN

• WZL• INA• IWU• Karl Mayer• ISW• Lernstatt

• Comau• Gamesa• Anayak• Fatronik

• Arjal

FRANCE• Lirmm

MACH21Mach21 in EMO 2003

MACH21Mach21 in EMO 2003

MACH21 objectives

• The project MACH21 has meant an holistic or overall approach to PKMs in order to try to solve or minimize the most important generic problems that affected this technology at the beginning of the project, through the whole life cycle.

• This way the project bets for a modernisation of the production means and brings nearer the implementation phase of the parallel kinematics production technology in the industrial companies shop floors by improving the PKMs performances in the areas of accuracy, dynamics and flexibility.

MACH21Mach21 in EMO 2003

COMPONENTS-Joints & Struts

• Improved in behaviour telescopic struts and drives

• Optimized joints for a wide range of processes with different characteristics and problematic  

MACH21Mach21 in EMO 2003

PKM design assistance tools

Software programs and digital models for aiding the designers to assess and simulate the static and dynamic capabilities of a particular PKM architecture in a preliminary conceptual design stage

MACH21Mach21 in EMO 2003

Static and dynamic accuracy improvements

Drives: A1, A2

A2

forcelessmeasurementstructur

passive guidelines: P1 ... P4

P4

P3

P2

P1A1 rotaryencoder

Rz

New calibration methods and devices obtained for enhancing machine static accuracy

20

20

Methods to monitore and compensate static errors (gravity, thermal) not corrected by analytical model-based calibrations

Control strategies and algorithms for improving the dynamic accuracy

CartesianTrajectoryGeneration

C Robot

[Vector ofTOOL

positions]nx1

[EXTENDED positions](n+r)x1

[EXTENDED errors](n+r)x1

[Vector of EXTENDED

sensors measurements](n+r)x1

[EXTENDED to JOINT transformationmatrix](n)x(p+r)

[JOINT controller]

RKM

IKM

[Vector ofMODIFIED errors](n)x1

+-

TEJ

FKM (Robot User)

[Vector ofREDUNDANT

positions]rx1

[JOINT positions]nx1

Drives: A1, A2

A2

forcelessmeasurement

structur

passive guidelines: P1 ... P4

P4

P3

P2

P1A1

rotaryencoder

R

z

d x

d x

d x

K p

K v ) ( ~ x A

f d computation

ROBOT

H ~

t m J

) ( q h x

+ +

+

+

+

+ - -

f n

f d

q

dt dq /

w

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes

New PK designs ending in technology demonstrator prototypes for the following industrial processes and sectors:

– High dynamic handling prototype (automotive sector)– 5 axes horizontal milling prototype (aeronautic sector)– 5 axes vertical milling prototype (mould and die sector)– “Heavy Tow” fibers layer prototype (textile sector)– Thin panels assembly in skeletal structures of ribs and spars (virtual

prototype, aeronautic sector)

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes (I)

4 DOF high dynamic handling prototype (automotive sector)

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes (II)

• 5 axes horizontal milling prototype (aeronautic sector)

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes (III)

5 axes vertical milling prototype (mould and die sector)

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes (IV)

“Heavy Tow” fibres layer prototype (textile sector)

MACH21Mach21 in EMO 2003

Demonstrators/Prototypes (V)

• Thin panels assembly in skeletal structures of ribs and spars (virtual prototype, aeronautic sector)

MACH21Mach21 in EMO 2003

MACH21: the snowball effect

• EMO2003: the fist time in history for a specific classification of PKM machines.

• 16 first-class manufacturers offering market ready PKM machines at the EMO2003

• 4 components suppliers for PKM machines at the EMO2003

• 14 of these companies have relation with MACH21 or their partners.