For the refurbishment of a large industrial lathe (SKIQ161) at project partner TOSHULIN, FRAUNHOFER IWU is developing digital twins for path accuracy and remaining useful life to increase the quality and performance of the machine while decreasing downtimes. The digital twin is based on a mechatronic model describing the structural mechanics of the machine as well as the control loops of all feed drives. The model predicts dynamic displacements at the tool centre point by continuously readout internal control signals such as the commanded and measured position at each feed axis. The transparent visualization of the predicted displacements can be used to optimise machine parameters such as the acceleration and jerk of the feed drives resulting in lower cycle times of the processes and/or increased quality of the parts. The identification of the model parameters and verification of the results is done via experiments, where additional sensors are temporarily installed at the machine tool. As a first step, the implementation of the digital twin for path accuracy at a turning milling centre in the laboratory of FRAUNHOFER IWU has now been realized and demonstrated. Next steps consist in the qualification of the digital twin for the prediction of the remaining useful life of critical components.
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