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Concept of Developing a Gear Selection Tool for Improved Accuracy in Industrial Robotics

Yaqoob Muhammad Faisal, Gollee Christian, Schenke Christer-Clifford, Ihlenfeldt Steffen

Journal of Machine Engineering

2025

Vol. 25, No. 2

138--148

The application of robotics has evolved significantly through every industry. Robots do provide a wide range of motion, however their advantage of having lightweight components also limit the rigidity of the tool center point. Compensatory techniques involving joint stiffness determination and model-based predictions is one potential approach while another modern solution is the usage of precision gears. Higher rigidity and lower backlash found in precision gears as compared to conventional gears enable increased accuracy when carrying out production processes with industrial robots. A study at Fraunhofer IWU confirmed this by examining the impact of precision gear on a six-axis robot's accuracy during a milling process. Replacing all gears with precision gear technology or building new robots with them will certainly increase process accuracy. However, with over a half million robots already installed worldwide, there is a definite need to streamline the gear selection while enhancing the accuracy of existing robots with minimal effort and cost. This paper presents a proof of concept to develop a gear selection tool which utilizes robot’s MBS (multibody simulation) model involving gear parameters and process requirements to simplify gear selection for industrial processes. This tool aims to address the question “Which gear(s) needs to be replaced/installed in a robot to achieve the required/improved movement accuracy for an existing or new process?”

Concept of Integrating a Hybrid Thermal Error Compensation Into an Existing Machine Tool Control Architecture

Geist Alexander, Yaqoob Muhammad Faisal, Friedrich Christian, Naumann Christian, Ihlenfeldt Steffen

Journal of Machine Engineering

2024

Vol. 24, No. 3

32--36

Thermal error compensation via a numeric control (NC) system is a proven option for upgrading the precision of machine tools. The main advantage is the generally cost-effective application, as no changes to the machine design are necessary. Since modern machine tools are equipped with standard numeric controls along with additional functions and integrated temperature sensors in the machine, compensation methods such as a characteristic diagram (CD) based compensation can be implemented. To increase the applicability and reliability of this CD regression method, a hybrid model approach with a virtual thermo-elastic finite element (FE) machine model and a real-time computable structural model of a machine tool was developed. The structural model uses model order reduction to calculate the current load case in real-time using continuously recorded machine data (motor current, axis position, temperatures). It acts as a virtual monitoring application to check, whether the current machine condition still matches the current CD based prediction. If the current load case is not suitable to the active CDs or any other stored CDs, the generation of new CDs is automatically triggered. In this article, the integration of the hybrid compensation method using an FE model and a structural model of a machine tool is methodically demonstrated. The main focus is on the integration of different software and hardware architectures and their interaction.