TEKNIKER: Process control using FINGERPRINT for Machine Tools
TEKNIKER is a technology center specialized in Advanced Manufacturing, Surface Engineering, Product Engineering and ICTs for manufacturing. Its mission is focused on bringing growth and wellbeing for society through R&D&I actions and by furthering the competitiveness of the surrounding industrial fabric in a sustainable manner. Participation in powerful EU funded projects, like InterQ, guarantees the excellence in the different fields of expertise.
TEKNIKER activities in InterQ are aligned with its Advanced Manufacturing research area and its main objective is to develop functionalities to improve manufacturing process. Hence, apart from being part of InterQ technical coordination team, TEKNIKER has a relevant role in InterQ-Process (WP2) and InterQ-ZeroDefect (WP5) modules. In addition, TEKNIKER is also involved in the industrial demonstrator stage due to the close collaboration with the energy use case (GAMESA Energy Transmission).
TEKNIKER technical activities move around a functionality to control the condition of machine tools, called FINGERPRINT. This functionality is based on a repetitive and controlled sequence of movements, avoiding the effect of manufacturing process, that provide relevant information about machine performance. A high frequency monitoring system, combined with a model-based post-processing allows converting the raw data acquired during the test into KPIs directly related to component condition as backlash or friction. To properly trace machine condition over time, the test is fast, to avoid productivity reduction, and automated, to avoid
new skill requirements for operators.
The FINGERPRINT functionality is being complemented in InterQ by adding new KPIs to determine the geometric condition of the machine tool. In this sense, two approaches are being developed for a fast characterization: the usage of calibrated artifacts and the integrated multilateration.
The latter consists in a novel approach where a laser tracker is integrated in machine tool spindle, as an additional tool, and measures the distance to different reflectors at several positions of the machine tool. This approach reduces the duration of volumetric error measurements to the 10-20% of the time needed in conventional approaches.
Apart from the implementation in its own lab machines, the functionality is currently installed and being used in the energy use case, with four different machine tools where the FINGERPRINTs are executed every week. Raw data and indicators are automatically sent to TEKNIKER Smart Factory Hub platform after each test, where results can be analyzed and visualized.