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Ik4: avant-garde technology for machine tools of the future - Precision Machining Parts Manufacture by na b
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Ik4: avant-garde technology for machine tools of the future - Precision Machining Parts Manufacture by NA B
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| Article Posted: 08/27/2012 |
| Article Views: 101 |
| Articles Written: 2638 - MORE ARTICLES FROM THIS AUTHOR |
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Ik4: avant-garde technology for machine tools of the future - Precision Machining Parts Manufacture |
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Business,Business News,Business Opportunities
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Avant-garde technology for machine tools of the future Ultraprecise laser equipment, advanced inspection and measuringtechnologies for the railway industry or advanced robotics for theautomating of artisanal processes are just some of the developmentsthat the IK4 Research Alliance will be presenting at theforthcoming Machine Tool Biennial, to take place at the BilbaoExhibition Center (BEC) from 28 May to 2 June. IK4 will have the support of two of its partners: the R+D centresIK4-TEKNIKER and IK4-IDEKO, benchmarks in the machine-tool sector,and which in recent decades have achieved a high degree ofspecialization; this allows them to put their advancedtechnological developments at the service of a whole range ofapplications. Visitors heading for the stand located between aisles C08 and D09of pavilion no. 1 in the Bilbao Exhibition Centre will be able tosee first-hand a whole range of advanced technologies designed byIK4 at the service of machine tools.
The functioning of theseinnovations of IK4-TEKNIKER will be all the more visible though aspectacular visual presentation based on 3D mapping (sample videoof this technology). IK4-IDEKO will be showing two micromachiningprototypes arranged in the form of cell that will produceintraocular lenses in situ. Both IK4-TEKNIKER and IK4-IDEKO are active members of CIC marGUNE,the Co-operative Research Centre involved in High PerformanceManufacturing. So they work together on important high technologyresearch projects like Hiperión, which is aiming to positionthe Basque machine tool sector as the first purchase optionworldwide in Precision Machining Parts machines for large-sized parts.
The sum of the capabilities of the two centres constitutes thebroadest and most powerful offer of manufacturing technologies inSpain, which puts them on the level of benchmark countries in thissector. IK4-TEKNIKER and IK4-IDEKO are collaborating closely withinthe IK4 Alliance by working together, optimising research costswith public funding, and customising technology transfer in anindividual way and tailored to the client. The pieces of equipment that the two R+D centres will be exhibitingin their joint pavilion at the Bienial are prototypes destined formachine tools and which reflect the potential of IK4-TEKNIKER andIK4-IDEKO as technological benchmarks for this sector; they are asfollows: Advanced developments in laser equipment IK4-TEKNIKER and IK4-IDEKO will each be presenting at the BECdevelopments of laser equipment with applications for sectors thatrequire the utmost Precision Machining Parts, like the medical sector, aeronauticsor the automotive sector. IK4-TEKNIKER will be showing a laser prototype designed to carryout welding; the centre has developed the mechatronic part and thehigh-powered diode laser with 100% in-house technology.
The weldingof plastic components by means of fibre-optic guided laser is atechnique that has been recently introduced into industry and whichoffers advantages over other conventional methods: it does awaywith chemical adhesives, minimizes thermal distortions in thewelding section, and offers greater efficiency and greaterflexibility. IK4-IDEKO will be presenting a three-axis laser ablation machinethat can work with three pulsed laser wavelengths at intervals ofpicoseconds. These ultrashort picoseond pulses make possible highquality operations with applications that focus, above all, on themedical sector as well as on the automotive sector, theaeronautical sector or renewable energies. Technology applied to the railway industry At the Biennial IK4-IDEKO will be presenting an innovative solutionfor inspecting and measuring train wheel profiles.
Currenttechnologies require that the railway track be modified, soinstalling them requires undertaking civil engineering works tobuild specific tracks with limited features. The R+D centre has developed a new measuring system based on 3Dmulti-camera technology for the integral measuring of the geometryof the wheel; this does away with modifications to the track and iscapable of carrying out simultaneous measurements preliminary to acomplete profile. What is more, the measuring system, thanks to aninnovative 3D reconstruction model, allows the wheel profile anddiameter to be measured precisely without the wheel needing to turnwith a predetermined, controlled alignment. This innovative systemfor the railway industry is in the patent application process. Robotics for complex processes The automation of production systems enables production to becontrolled automatically either totally or partly by means ofrobots.
The result is greater productivity and an improvement inthe working conditions of people. IK4-TEKNIKER is working on theevolution of traditional manufacturing systems by means of roboticsby developing improvements in the production mechanism, optimisingits processes and developing sustainable systems to achieve faster,more efficient production. IK4-TEKNIKER is presenting at the Machine Tool Biennial the"Robofoot" project that is a robotised cell prototype inwhich a robot manufactures and inspects footwear. The R+D centrehas decided to show this development to convey the idea that eventhe most labour-intensive processes lend themselves to being"robotised" to improve the quality of the finalproduct, staff working conditions, and to maximise the efficiencyof plants by means of 2D vision technology in the inspectionmodule, and technologies for the dynamic generation of trajectories(Visual Servoing) to locate the footwear. Solving machine vibrations Vibrations constitute one of the most common and serious problemsnot only for the quality of the final product in the machiningprocesses, but also for the integrity of the machine itself.
Thatis why IK4-IDEKO is presenting at the Biennial an inertialelectromagnetic shock absorber and a signal acquisition andprocessing platform for machine tools entirely developed by the R+Dcentre. The active shock absorber is an electromagnetic device speciallydesigned to be coupled to the machine"s mechanical structureand insert a controlled force into it. This force is regulated bymeans of advanced control techniques to increase theshock-absorbing capacity of the structure, whereby the vibrationsare drastically cut. This device has managed to eliminate chatter in milling, turning and grinding. As regards the acquisition and processing platform, this equipmentallows ICP piezoelectric accelerometer signals or selectablevoltage signals to be captured by means of acquisition software, sothat the evolution in time of the signal acquired can subsequentlybe displayed and a spectral analysis conducted.
Advanced manufacturing technologies Developments in advanced manufacturing technologies which the twomembers of the IK4 Alliance will be presenting at the Biennial willconfirm the credentials of these two R+D centres in this field. IK4-TEKNIKER is proposing an ultrasound machining and manufacturingsystem that allows a whole range of applications for sectors likethe automotive sector, aeronautics or medicine in which work isdone on materials that are difficult to process by means of othertechniques. IK4-TEKNIKER will have a demonstrator of an ultrasoundrotary machining process; it is based on the removal of materialthrough the combination of turning and vibration in an axialdirection using a super-abrasive tool. This process offers significant advantages over other types ofprocesses as it reduces cutting effort, the thermal load on thepart, and as a result, the wear and tear sustained by the tool.Likewise, removal rates are increased (up to 5 times higher thanthrough grinding), a good surface finish is obtained, and theprocess produces a surface layer of residual compression stresses,thus increasing fatigue life.
For its part, IK4-IDEKO will be showing an Precision Machining Parts lathewith an aerostatic head for turning. The Precision Machining Parts lathe hasthree axes for machining optical quality parts and is mounted on agranite structure to increase its stability in the event oftemperature changes. The aerostatic Fast Tool Servo (FTS) head allows rapid action ofthe tool for turning with a diamond point; this facilitates thegeneration of free geometric shapes with applications like thegeneration of spherical surfaces to improve the finish of opticallenses. This device will be on show at the Biennial as an accessoryfor the laser equipment displayed by IK4-IDEKO on the same stand.Both pieces of equipment will make up a complete production linefor intraocular lenses. The R+D centre will also showing a parallel kinematic tabledesigned for the rapid and accurate positioning of photovoltaicwafers.
This device has been designed to correct positioning errorsin photovoltaic wafers during manufacturing; it makes use of avision measuring system compensated by the movement of the table, atechnique that makes a high productivity, low-cost solutionpossible. Sustainability in manufacturing and industrial productiontechnologies IK4-IDEKO will be presenting at the Biennial optimum coolingECO-JET nozzles for grinding processes. This is a large range ofnozzles with an adaptable design, guaranteeing a reduction ofbetween 25% and 50% in the loss of the system's load. Their use enables productivity to be increased in the processes anda corresponding cost reduction per part through various means:increase in the useful life of the grinding wheel, reduction in thediamond dressings, increase in the time between the diamonddressings, the possibility of using greater removals through thereducing of friction and heat in the machining area, etc.Furthermore, this system brings improvements in the stability and Precision Machining Parts of the processes and cuts the costs associated with thesizing and performance of the cooling equipment.
IK4-IDEKO belongs to the European Blue Competence initiative of themachinery sector which is geared towards sustainability. Thecommitment as a result of this initiative reflects the R+Dcentre"s commitment to the design of machines that areenergy-efficient in the use phase, in their orientation towards theconsumption of environmentally-friendly raw materials, theoptimized use of cutting and cooling fluids, as well as acommitment to sustainable manufacturing processes. 3D Technology put to use for gaining Precision Machining Parts in the large machinetool IK4-TEKNIKER will also be showing a new system for the volumetricverification of the positioning of large-sized machine tools inorder to meet the growing demand of companies for systems with fullgeometrical verification systems. The system uses 3D technology to measure positioning accurately,and makes use of the most innovative measuring equipment in thefield (the Leica AT901-MR laser tracker and the Wyler BlueLEVELlevels), supported by a robust, multilateration-based framework.
The result is an advanced service that can be rapidly executed, andwhich allows the positioning error in the complete volume of themachine to be characterised, by providing a measurement uncertaintythat suits the needs of the application. The reduction in the time needed to carry out the verification ofthe machine"s positioning means greater stability in theresults, and cost savings. A set of geometric parameters(straightness, rectangularity and linear positioning) are obtainedfrom the results of the measurements. These allow one to get abetter understanding of the machine and even to feed a compensationsystem. Elektronika, Enpresa, Ikerketa-zentroak, Industria, Teknologia Go to top of page.
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