Fraunhofer Institute for Production Technology IPT
Fraunhofer Institute for Production Technology IPT
© Fraunhofer IPT

Increasing machine precision

We optimize the geometric, thermal and dynamic behavior of your machine and develop tailored solutions.

© Fraunhofer IPT

© Fraunhofer IPT

Intelligent retrofitting

Retrofitting old machines made easy. Have your old machines retrofitted quickly and effectively and achieve modern accuracies.

© Fraunhofer IPT

Analyzing and characterizing machine properties

The precision of machine tools is extremely important for the manufacture of high-quality products used in various industries such as automotive engineering, aerospace engineering and medical technology.

By using machine characterization tools, users can identify, analyze and optimize geometric, static, thermal and dynamic machine properties. Fraunhofer IPT has accumulated considerable expertise in this domain through extensive research over many years, and now possesses a comprehensive range of modern measuring instruments for investigating various machine types and kinematics.

Modern measuring instruments: The key to high-precision machines

Suitable measuring equipment helps to identify machine errors: Benefit from a variety of measuring instruments that provide you with the right tool for every use case. Take a look at our measuring equipment portfolio!

Deep process knowledge creates solutions

When machined parts suddenly go out of tolerance, machine operators often have no idea what caused the problem. Together with our customers, we develop methods to ensure high machine accuracy. We assist machine users in process optimization, as well as custom machine builders and machine manufacturers in the development of high-precision machine tools.

Our customer-specific services at a glance

  • Machine characterization and optimization as a service (comprehensive on-site analysis)
  • Software solutions & training for long-term customer empowerment
  • Licensing of optimization methods for machine tool manufacturers

Accuracy optimization of high-performance production machines

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Geometry

Geometric errors in machine tools are caused by tolerance-related deviations from target geometries, but also by wear and assembly-related errors. Machine calibration can reduce these errors. We have the technical expertise and measuring instruments to perform high-precision calibrations that can be automatically integrated into your production process. This allows you to quickly and cost-effectively achieve the optimum operating condition of your machine tool.

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Thermal

Thermal instability is the most common cause of workpiece errors and production waste. Conventional solutions measure temperature differences and indirectly derive the TCP (Tool Center Point) displacement. Fraunhofer IPT system takes the direct route and avoids model-related information loss. We can measure the deformations of the machine structure directly and parallel to the process and calculate the volumetric TCP displacement. The sensor system can be individually adapted to your milling, turning or grinding machine, as well as to other special machine types.

© Fraunhofer IPT

Dynamics

We help companies analyze and optimize dynamic machine behavior, including vibration, dynamic stiffness, damping characteristics and operating noise, to improve the performance and lifetime of their machines. We perform frequency response and modal analysis and use simulation to examine the machine’s structural components.

Products and services

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Retrofit vBox

Our compact system for data acquisition (DAQ), the vBox, offers users the option of connecting various commercially available sensors centrally and saving aggregated data in real time. In addition to digital inputs and outputs, the established BNC interface can also be used to record position data and other analog signals, for example. Since the vBox is highly compatible with the BNC interfaces and has simple measurement setup, it can easily be retrofitted into existing machines. All common platforms and frameworks can be connected thanks to highly configurable software with numerous interfaces (MQTT, OPC UA, InfluxDB, ...).

 

Digital twin

Modern measuring systems record forces, currents and acceleration as well as position and other machine data. With the appropriate software, we are now able to create an exact digital image of the workpiece to be manufactured throughout the entire production process, display it effectively and clearly, and retrieve it again if required. Using the digital twin, users can check the quality of the manufactured workpieces while the process is still running and to recognize when reworking will be necessary at an early stage.

digitale Zwillinge nutzen
 

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R-test

Fraunhofer IPT has identified the necessity of efficiently, cost-effectively, and rapidly identifying relevant geometric errors of 5-axis machine tools. The R-test, also referred to as the chase-the-ball method, is a measurement procedure by which all machine errors can be identified simultaneously.

R-test applied

Dissertations and publications

Journal article

M. Dehn, F. Plum, N. Bertaggia, S. Neus, D. Zontar and C. Brecher, "Modeling the thermal machine tool error during cooling lubricant usage," Procedia CIRP, vol. 120, pp. 1179–1184, 2023, doi: 10.1016/j.procir.2023.09.145 .

Journal article

N. Bertaggia, F. Tzanetos, D. Zontar and C. Brecher, "Investigation of thermally induced TCP-displacement under load of the machine axes in different areas," Procedia CIRP, vol. 107, pp. 600–604, 2022, doi: 10.1016/j.procir.2022.05.032 .

 

© Fraunhofer IPT

Dissertation

Schäfer, C.: Signaltechnische Voraussetzungen und Analyseverfahren zur Überwachung von Präzisions- und Ultrapräzisionsbearbeitungsverfahren. Diss. RWTH Aachen, 2013

 

Dissertation

Flore, J.: Optimierung der Genauigkeit fünfachsiger Werkzeugmaschinen. Diss. RWTH Aachen, 2016

A look at our measuring equipment portfolio

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The Trinity probe is a wireless measuring head that is equipped with three eddy current sensors and is able to record the displacement of the machines TCP in relation to a measuring sphere in three dimensions. This device therefore can be used to measure a large area of the working volume of the machine tool within a short period of time. We perform discrete and continuous measurements to capture the geometric and thermal characteristics of the machine.

Laserinterferometer

We use a laser interferometer to measure the geometrical deviations of a machine tool: Our measuring systems and optics help us to identify positioning deviations, straightness deviations, angular deviations of a linear axis and rectangularity of the movement axes.

PSD Laser instrument

© Fraunhofer IPT

The position-sensitive-device (PSD) can usefully be deployed in conjunction with a laser whenever there is straightness deviation in a linear axis. The advantages of this is the straightforwardness of use along with ease of installation, opening up the way for swift and robust measurement.

Laser Tracer

We deploy the »Laser Tracer« manufactured by Etalon AG to characterize machines with maximum precision. With its self-tracking function, the laser tracer follows the optical lens in order to reproduce three-dimensionally any changes in the distance from an object. Examples of its use include the complete calibration of 3-axis and 5-axis machine tools with different axis configurations and the acceptance and testing of coordinate measuring machines in accordance with ISO 10360.

Spindle Error Analyzer

© Fraunhofer IPT

The »Spindle Error Analyzer« is used to measure the accuracy of rotating spindles: The exact position of a sphere on the tool is measured by sensors working from different directions in very high frequency. The thermal properties of the rotating spindle can also be analyzed.

Double Ball bar

We deploy the »Ball-bar« to coordinate the path behavior of two motion axes: Geometric and dynamic deviations of the machines can be measured very swiftly via the circularity test, defective machine elements and adjustment faults can be identified and compensation and control parameters can be optimized. Used in conjunction with additional instruments, the ball-bar supports a range of analyses via the circularity test in three radii (50 mm, 150 mm and 300 mm).

Multi-functional measuring unit for modal and harmonic response analyses

We work closely with the Machine Tool Laboratory WZL RWTH University of Aachen to analyze dynamic machine behavior. This gives us access to additional measuring equipment and extensive know-how which enables us to provide an even more multi-faceted, dynamic characterization of machine tools.

Thermographic camera

The thermographic camera is used to measure the surface temperature of an object and to present it on an integrated display. The thermal behavior of the machine and associated processes can be analyzed on the basis of the measurement data.