Hardware-in-the-Loop Machine Simulation for Modular Machine Tools

Abstract

One of the most recognized trends in production today is the increasing demand of complex and personalized products. This leads to an increasing demand for machine tools. As a consequence machine tools are required to be adaptable and modifiable for different products or different conditions. To fulfill this precondition while keeping up or increasing productivity, the concept of modular systems is used nowadays to design and manufacture machine tools. However, during the first steps of planning new production processes neither the customer nor the manufacturer of a new machine tool knows the resulting effectiveness of the composed machine tool configuration. Currently assumptions on the effectiveness are made based on experience or comparative processes. This paper presentsa method for a hardware-in-the-loop machine simulation, which can be used to optimize the design process of machine tools based on modular systems. This machine simulation should automatically adjusts the virtual model according to the current machine tool configuration, taking into account 3D geometry, kinematic structure and its performance characteristics, e.g. acceleration and velocity. The specific configuration of the machine not only affects the virtual model but also the necessary configuration of the real CNC, which also influences the hardware-in-the-loop coupling needed for the simulation. Using a machine simulation with the developed methods will increase the quality of estimations during the first planning phases, thus improving the decision making process. Additionally, the communication between the manufacturer and the customer will be optimized by applying this method for sales and distribution. This paper describes first steps to create such a machine simulation, by combining and adapting numerous methods.