New High-Speed Machine Tool Structure by Holistic Mechatronic Systems Design

AbstractOne possibility to increase the performance of machine tools is the achievement of higher accelerations and jerks of moved slides and stands. By this the energy consumption and machining-costs can be optimized. Nowadays machine tool structures are already optimized and further enhancements are not easily achieved. The paper deals with the mechatronic system optimization of a large-scale HSC- and HPC- portal milling centre for e.g. forming tools. This includes the identification of dynamic limiting structures and the following optimization by mechatronic system-monitoring. From process necessities a machining-time reduction by higher accelerations and improved process stability is intended. The system parameters where achieved by the implementation of a redundant axis and the usage of up-to-date lightweight design by reinforced plastics.All over the design phase the structure was constantly monitored regarding their dynamic behaviour. Furthermore a model was used – using a state space – to prejudge the machining time for a concrete example cycle. So even before any physical prototype exists the mechatronic system-behaviour of the machine tool was pre estimated using a virtual mechatronic model. This allows for a virtual product design with a new and improved quality of safety in achieving the pre-defined goals