One of the most significant advances in the development of computer science, information and communication technologies is represented by the cyber-physical systems (CPS). They are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-accessing and data-processing services available on the Internet. Cyber-physical production systems (CPPS), relying on the latest, and the foreseeable further developments of computer science, information and communication technologies on one hand, and of manufacturing science and technology, on the other, may lead to the 4th industrial revolution, frequently noted as Industrie 4.0. The paper underlines that there are significant roots in general – and in particular to the CIRP community – which point towards CPPS. Expectations towards research in and implementation of CPS and CPPS are outlined and some case studies are introduced. Related new R&D challenges are highlighted.

Cyber-physical systems in manufacturing

Machine tools for large parts

Robots in machining

For the past three decades, robotic machining has attracted a large amount of research interest owning to the benefit of cost efficiency, high flexibility and multi-functionality of industrial robot. Covering articles published on the subjects of robotic machining in the past 30 years or so; this paper aims to provide an up-to-date review of robotic machining research works, a critical analysis of publications that publish the research works, and an understanding of the future directions in the field. The research works are organised into two operation categories, low material removal rate (MRR) and high MRR, according their machining properties, and the research topics are reviewed and highlighted separately. Then, a set of statistical analysis is carried out in terms of published years and countries. Towards an applicable robotic machining, the future trends and key research points are identified at the end of this paper.

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Industrial robotic machining: a review

Advances in Large-Scale Metrology – Review and future trends

Process monitoring with sensory machine tool components

Due to the advancements in high speed and high performance cutting, further improvements of machine component design and process monitoring are necessary. For this purpose, new machine components with process monitoring capabilities have to be developed. In this paper, a new spindle carrying Z-slide for a 5-axis machining center with integrated sensing capabilities for process monitoring is presented. First, the overall system design is described. The sensing capabilities to enable process monitoring are realized by application of a micro-strain gauges network on to the structure of the slide. The optimal sensor positions are computed by application of a special sensor placement algorithm. The prototype of the slide has been built up to investigate the system behavior. The electronic system of the prototype to realize the signal amplification and the communication via an industrial bus are presented. Furthermore, the results of the system analysis of the prototype are described. Because the sensor amplitudes, which can be monitored by strain gauges on stiff structures, are generally small, a method to increase these amplitudes by use of the notch effect and new micro-strain sensors is discussed. With this method, the signal amplitudes can be increased significantly, without degrading the stiffness noticeably. At the end of the paper a method to manufacture notches in the prototype by a milling process is presented. The surface roughness of plan notch ground, measured with a laserprofilometer, shows roughness values lower than 3 μm.

Design and analysis of a prototypical sensory Z-slide for machine tools

Recent increase in machine automation, machine capability, and the performance of machining processes lead to high demands on process monitoring systems. In the Center of Production Engineering in Hannover Gentelligent® manufacturing systems are researched, which will be able to meet those requirements. One enabling factor for these systems is the “feeling” capability, achieved by multi sensor systems. This paper copes with the design of these systems. This includes on the one hand the development of sensor configurations and on the other hand a concept for sensor fusion. For the search of optimum sensor configurations a previously developed algorithm is extended to consider the dynamic behavior of the sensor systems.

Kai Martin Litwinski

Papers

Process monitoring with sensory machine tool components

Design and analysis of a prototypical sensory Z-slide for machine tools

Design of dynamic multi sensor systems

Detection of tool deflection in milling by a sensory axis slide for machine tools

Process Monitoring with a Force Sensitive Axis-slide for Machine Tools