Analysis of dynamic deformation processes with adaptive KALMAN-filtering

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The analysis of dynamic deformation processes is an important task in civil and in mechanical engineering. One main emphasis is set on the derivation of the objects transmission function, represented by systems of ordinary or partial differential equations (“white box”-models). The parametric identification of the initial and boundary conditions and relevant material parameters is one of the new challenges in the application of least-square algorithms. Embedding the investigation of the deformation process in a combination of a theoretical and an experimental system analysis suitable methods are provided with adaptive KALMAN-filtering as central identification tool. In this paper the approach of a full system analysis is shown quantifying a dynamic “white-box”-model for the calculation of thermal deformations of bar-shaped machine elements. The task was motivied from mechanical engineering searching new methods for the precise prediction and computational compensation of thermal influences in the heating and cooling phases of machine tools (i.e. robot arms, etc.). The quantification of thermal deformations under variable dynamic loads requires the modelling of the non-stationary spatial temperature distribution inside the object. Based upon FOURIERS law of heat flow the high-grade non-linear temperature gradient is represented by a system of partial differential equations within the framework of a dynamic Finite Element topology. It is shown that adaptive KALMAN-filtering is suitable to quantify relevant disturbance influences and to identify thermal parameters (i.e. thermal diffusivity) with a deviation of only 0,2%. As result an identified (and verified) parametric model for the realistic prediction respectively simu-lation of dynamic temperature processes is presented. Classifying the thermal bend as the main deformation quantity of bar-shaped machine tools, the temperature model is extended to a temperature deformation model. In lab tests with an aluminium column control measurements show that the identified model can be used to predict the columns bend with a mean deviation smaller than 10 mgon. Consequently the deformation model is a precise predictor and suitable for realistic simulations of thermal deformations under variable dynamic loads. In future our activities will be primarily focussed on applications in industrial manufacturing. 1. Parametric identification of dynamic deformation processes The creation of a realistic parametric dynamic deformation model is directly associated with the task to combine systems of differential equations (theoretical physical model) with empirical measurements. Consequently basic principles of system theory can be adapted to the geodetic deformation analysis. The parametric identification of a dynamic “white box”-model 3rd IAG / 12th FIG Symposium, Baden, May 22-24, 2006