Machining with redundant kinematics

The demand for high productivity and quality combined with the need for decreasing energy consumption will substantially affect machine tool design in the future. This development is driven by a modification of process chains which is focused on resource conservation. One important contribution for that purpose is the transition towards complete machining. This approach calls for a configuration targeting major process stability as well as a structure geared towards accuracy and dynamism. The compromise between potential dynamism and machine size can be improved by using redundant drives. The realisable effects can reach from the pure increase of machine dynamic parameters to the integration of additional technology options such as micro structuring of surfaces. The advantageous use of redundancy requires the specialization on partitioning of the complete motion. With the presented algorithm the reactive sectioning of a multidimensional motion into two components with different dynamic characteristics succeeds. This provides a useful basis for the application of the principle of dynamic sectioning for a suitable design of drive redundant machine structures. This paper describes models, simulation tools and the method of the development process for redundant kinematics. Furthermore the realisation of such machine tool structures is demonstrated on the basis of complete machining for tool- and die making and an adaptive spindle holder for micro contouring and -structuring.