PI develops high-dynamic compensation kinematics

Physics Instruments PI develops high-dynamic compensation kinematics for aircraft construction

2024-08-06 Source: Press Release | Translated by AI 4 min Reading Time

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As part of the International Aerospace Exhibition ILA Berlin in June, Physics Instruments (PI) presented itself as a partner of the research project "LuFo VI-1": ADMAS (Advanced Machining and Sealing). Under the leadership of Airbus, PI has brought its more than 30-year expertise in the development of hexapods into the research project. The project, which was publicly funded by the Federal Ministry for Economic Affairs and Climate Protection and supervised by DLR Project Carrier Aviation Research, was successfully completed at the end of April 2024.

ADMAS system at IFAM in Stade: An articulated robot from Mabi Robotic, with a hexapod from Physics Instruments (PI), processes a CFRP component.(Image: Fraunhofer IFAM) — ADMAS system at IFAM in Stade: An articulated robot from Mabi Robotic, with a hexapod from Physics Instruments (PI), processes a CFRP component.
(Image: Fraunhofer IFAM)

As part of the joint project, PI developed the high-performance Hexapod H-900K101 for a highly dynamic compensation kinematics in aircraft construction. The aim was to increase machining and sealing precision for CFRP components in the RTM production process (Resin Transfer Molding) as well as to reduce production times and process costs. The composite material CFRP significantly contributes to more energy efficiency and CO₂ savings in aircraft due to its low weight and high rigidity.

Dynamic compensation of process forces

The focus of the compensation kinematics is the contour machining of Wing of Tomorrow Singleaisle wing shells made of CFRP by milling and deburring, as well as their subsequent sealing and the introduction of bores. Combined with a articulated arm robot for rough positioning, the PI hexapod serves for fine positioning of machining and sealing tools. "With the new Hexapod H-900K101, we have implemented a highly dynamic system that can accelerate a payload of up to 40 kg in the XY plane with up to 12,000 mm/s². The system is capable of dynamically compensating for high-frequency path deviations under the influence of process forces during milling," explains Dr. Christian Sander, Head of Technology Development Parallel Kinematics at PI in Karlsruhe. The newly developed hexapod system was designed for the specific edge and environmental conditions of the application and is thus optimized in particular for the time-critical manufacturing processes with the given tolerances of the aviation industry.

Precision positioning of tools

In addition to this high dynamics, the hexapod system offers fiber optic data transmission between the hexapod controller and driver electronics. Furthermore, the system is characterized by a very short latency when using the EtherCAT interface and sealed components according to protection class IP54. With fiber optic data transmission, the hexapod controller can be conveniently placed in the control cabinet outside the machining cell without affecting the versatility of the interface and controls the driver electronics from a distance of up to 100 m. For the EtherCAT interface, a deep integration of the EtherCAT functionality was realized in PI's controller and driver architecture. In the complex control loop for the compensation of path deviations between edge detection sensor technology, articulated arm robot and hexapod, the PI positioning system thus contributes only a minimal dead time. The reaction time in the EtherCAT control loop between position query and position command of the hexapod is 1.5 ms.

Lastly, in the "ADMAS LuFo" project, it was investigated to what extent the use of acceleration sensors is useful for wear detection on individual legs of the hexapod as part of condition monitoring. The frequency spectrum of oscillations within a single leg can be assigned to characteristic natural frequencies of drive components and thus serve as an indicator of system changes.

Modular systems

Hexapods offer six degrees of freedom of movement in the most compact space. For industrial applications, combinations of absolute measuring position sensors, software, and motion controllers are available, which can also command complex motion profiles. All drive technologies can be individually adapted.

Precision hexapods from PI are available in the standard version for loads from 1 kg to 250 kg and repeat accuracy up to ±0.06 µm. Custom precision hexapods can carry loads of more than 2,000 kg. With travels of a few millimeters to several 100 millimeters, the machines allow precision up to the nanometer range and speeds from 0.1 mm/s to 500 mm/s. PI's hexapods are used worldwide in silicon photonics, automation, medical technology as well as astronomy and research. Depending on the requirement, they can be specified for environmental conditions such as IP54, laboratory, clean room, high vacuum, and ultra-high vacuum.

About Physik Instrumente (PI)

PI, headquartered in Karlsruhe, Germany, is a market and technology leader for high-precision positioning technology and piezo applications in the market segments of industrial automation, semiconductor industry, photonics, microscopy, and life sciences. Working closely with customers from all over the World, the more than 1,700 specialists at PI have been pushing the boundaries of what is technically possible for more than 50 years. The basis for this is a variety of drive technologies, in-house developed sensor technology, electronics as well as control and regulation technology. The range extends from components to subsystems to custom-made complete solutions. Over 560 granted and applied patents underline the company's technological leadership claim in precision positioning and piezo technology. PI is represented worldwide with nine manufacturing sites in Europe, North America, and Asia as well as 16 sales and service subsidiaries.

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This article was first published on our sister website 'SMM Schweizer MaschinenMarkt" (German Edition), Vogel Communications Group

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