Industrielle Steuerungstechnik (Germany)

Conventional CNC controllers, originally developed for machine tools, are increasingly used to control robotic systems. However, their decentralized axis structure and kinematic abstraction limit dynamic performance compared to dedicated robot controllers. To address this limitation, this paper presents a methodology for integrating dynamics-based feedforward control within CNC-controlled robots by reusing digital twins from virtual commissioning. The approach extends existing virtual models with inverse dynamics through standardized interfaces and deploys them directly on the CNC controller as real-time digital twins. These models generate feedforward torque signals that complement conventional feedback control, improving trajectory tracking without modifying the CNC architecture. The main contibution lies in a generalizable workflow that links simulation, commissioning, and operation within a unified framework. The method is validated experimentally on a Delta robot, demonstrating significant reductions in tracking error and showing that the approach can be readily adapted to other CNC-controlled robotic systems.

Carbon Capture and Utilization (CCU) bezeichnet die Abscheidung von CO2 aus industriellen Prozessen sowie dessen stoffliche oder chemische Weiterverwertung. Die vorliegende Studie untersucht CCU-Technologien mit besonderem Fokus auf den Bereich Utilization und analysiert deren Potenziale für mittelständische Unternehmen, insbesondere in der chemischen Industrie. Im Zentrum stehen CCU-Lösungen, die modular, dezentral einsetzbar und regional integrierbar sind und ohne spezialisierte Infrastrukturen wie eine Wasserstoffversorgung auskommen. Die Studie zeigt insgesamt, dass CCU für den Mittelstand ein strategisch relevantes Zukunftsfeld darstellt, das gezielt zur Erschließung neuer Märkte und Geschäftsfelder in innovativen und nachhaltigen Bereichen als sogenannte "First-Mover" genutzt werden kann.

ZusammenfassungBei der virtuellen Planung, Auslegung und Inbetriebnahme steigen die Anforderungen an die Aussagekraft Digitaler Zwillinge, um eine umfassende Absicherung und Auslegung im digitalen Entwicklungsprozess zu erreichen. Die Zunahme der Modellkomplexität eines Digitalen Zwillings stellt die Echtzeitsimulation durch den steigenden Berechnungsaufwand vor neue Herausforderungen. Dieser Beitrag stellt eine Plattform zur Echtzeit-Co-Simulation von Digitalen Zwillingen für die Virtuelle Inbetriebnahme vor. Die im Beitrag vorgestellte parallelisierte Modellberechnung auf Basis einer Co-Simulationsarchitektur beabsichtigt die zur Modellberechnung nutzbare Rechenleistung zu steigern. Der Beitrag führt (i) in die Integration leistungsfähiger technologiespezifischer Simulationslösungen durch Integrationsschnittstellen und (ii) die Echtzeit-Co-Simulation von Produktionsanlagen auf Basis von Partitionierungs-, Parallelisierungs-, Synchronisations- und Datenaustauschmechanismen ein.

ZusammenfassungUm hochwertige Automatisierungslösungen mit kontinuierlich steigendem Softwareanteil anzubieten, sieht sich der Maschinen- und Anlagenbau der Herausforderung von steigendem Testaufwand und steigender Testkomplexität gegenüber. Der in einer Virtuellen Inbetriebnahme eingesetzte Digitale Zwilling bildet in diesem Beitrag die Basis für die Entwicklung einer Effizienzmethode, um den Testaufwand durch Automatisierung zu reduzieren und die Testkomplexität beherrschbar zu machen. Dieser Beitrag erarbeitet die aktuellen Defizite der Virtuellen Inbetriebnahme im Softwaretest des Maschinen- und Anlagenbaus und präsentiert eine Lösung zur Testautomatisierung. Das entworfene Testautomatisierungswerkzeug ermöglicht mit einer methodischen Testplanung und -durchführung die frühzeitige Behebung etwaiger Softwarefehler. Damit steigt die Qualität der Software deutlich und gleichzeitig wird der Aufwand der Testabläufe reduziert. Der Umfang der Testlösung wird beispielhaft an einem Bearbeitungszentrum aufgezeigt.

Abstract The challenges in automation system development are driven by short development cycles and individualization along with resource‐constraints. State of the art solutions do not provide the necessary digital tools to apply model‐based methods in automation engineering to achieve higher performing systems. To overcome these issues this paper presents a novel approach to address some of the current challenges in automation systems development using digital twins with extended dynamic behaviour. The study underscores how dynamic models can be imported through standardised interfaces into virtual commissioning (VC) tools, improving the development process by effectively utilising domain‐specific expertise. The paper highlights how these digital twins enhance not only the VC process but can also be applied to model‐based control methods. Initial experiments showcase the utility of digital twins in calculating dynamic acceleration limits during trajectory planning of CNC control and enhancing feed‐forward control. Further, the importance of parameter identification in achieving accurate system models is stressed. The initial results are promising, and future work aims to combine these methods in an industrial application involving a newly developed, individual lightweight robot, demonstrating the potential for enhanced design, accelerated development, and resource efficiency in automation systems.

Abstract The main objective of virtual commissioning is to help design and validate the control systems of entire production plants. Therefore, simulations on a logical and kinematic level are performed, typically in a Software- or Hardware-in-the-Loop configuration using the original control software and controller [1].However, the lack of level of detail means that this type of simulation is insufficient for an integrated system dynamics and control algorithms design. These engineering tasks are currently performed in separate tools, e.g. by finite element analysis, multibody simulations or by a combination, i.e. elastic multibody systems (EMBS) [2]. However, the designed components are only considered individually and not in the context of the control technology used. Therefore, primarily synthetic inputs are used and not the original control behavior. With a higher level of simulation detail, further questions about the system, such as the effect of control algorithms on the dynamic processes, can be virtually validated.Therefore, this paper explores hybrid component-based digital twins to combine the advantages of both VC and EMBS. Hybrid components allow the simulation of the interactions between process, machine and control system with a high level of detail where this is beneficial. Such integration is achieved using the Functional Mock-up Interface (FMI) to couple different simulation models in a co-simulation environment [3]. This is demonstrated in a simulation use case of an inverted pendulum. The level of detail of individual components in the virtual commissioning tool ISG-virtuos [4] is increased by the modular integration of elastic multibody simulations via FMI so that the swing-up controller can be designed in the simulation.

Exchangeability of machine tools requires identical results of identical machining operation. For estimating the behaviour of machine tools, which are highly integrated mechatronic systems, the interaction of electromechanic system and controller must be observed together. Furthermore, it is possible to measure friction at start-up in serial production of machine tools and at the production plants of machine tool consumers without any additional measuring equipment. By these measurements of friction severe variances of behaviour of feed axes have been detected. These are mainly caused by assembly variances. Especially the alignments and preloads of bearings and ball screw have a strong effect because these components have a high stiffness. This means even smallest deviations result in high constraining forces, which directly affect the friction behaviour. Since it is impossible to determine the reasons of these variances in completely assembled machine tools, a test stand of a ball screw driven axis is examined. This test stand allows both detailed identification of components’ friction behaviour and definite variations of assembly conditions, namely alignment and preload, of bearings and ball screw nut. Hence a detailed investigation of effects of assembly variations becomes possible and has been conducted for alignment of ball screw nut and loose bearing. However, by this examination only the effects on the complete system can be examined but not the situation of constraining forces within the components. The knowledge of these internal forces is important because they directly affect the life expectancy of components and therewith feed drives. In order to improve the significance and to estimate the effect of assembly variances in detail, a modelling method based on multibody simulation has been developed and verified by comparison of measuring results of the test bed and simulation.