SOMMACT Self Optimising Measuring MAChine Tools Grant Agreement no.: CP- FP 229112-2 PROJECT FINAL REPORT PROJECT FINAL REPORT Grant Agreement number: CP- FP 229112-2 Project acronym: SOMMACT Project title: Self Optimising Measuring MAChine Tools Funding Scheme: Cooperation Period covered: from: 2009-01-11 to: 2012-08-31 Name of the scientific representative of the project's co-ordinator, Title and Organisation: Renato OTTONE, Mr., ALESAMONTI S.r.l. Tel: +39 348 4106 508 Fax: +39 0332 730028 E-mail: [email protected] Project website address: www.sommact.eu File:SOMMACT_Final_Report.docx SOMMACT Self Optimising Measuring MAChine Tools CP- FP 229112-2 Final publishable summary report PROJECT FINAL REPORT Table of contents 1 Executive summary ........................................................................................................................ 4 2 Project context and objectives ....................................................................................................... 5 2.1 Challenges within the current industrial context ..................................................................................... 5 2.1.1 State-of-the-art of relevant technology ........................................................................................ 5 2.1.2 Present context in the numerical compensation of geometric errors .......................................... 5 2.1.3 Market awareness ....................................................................................................................... 6 2.1.4 Lack of support for the determination of geometric errors and for the validation of the effectiveness of applied compensations ..................................................................................... 6 2.1.5 Current methods for on-machine inspection ............................................................................... 6 2.2 SOMMACT responses to existing industrial challenges ......................................................................... 6 2.2.1 Performance/research indicators ................................................................................................ 6 2.2.2 Building market awareness ......................................................................................................... 7 2.2.3 Advanced solutions for numerical compensation of geometric errors ........................................ 7 2.2.4 Traceable on-machine inspection ............................................................................................... 8 3 Description of main S&T results/foregrounds ................................................................................ 9 3.1 Specific measurable objectives attained by the project .......................................................................... 9 3.1.1 Enhanced machining accuracy ................................................................................................... 9 3.1.2 Traceable on-machine inspection capabilities ............................................................................ 14 3.1.3 Measurement of 6 degrees of freedom ....................................................................................... 16 3.1.4 Dynamic update of volumetric compensation tables .................................................................. 22 3.1.5 Standardisation of compensation tables ..................................................................................... 25 3.1.6 Self-optimisation of the geometric compensation ....................................................................... 26 3.1.7 Assistance to decision making .................................................................................................... 26 4 Potential impact ............................................................................................................................. 27 4.1 The metal cutting machine tool market ................................................................................................... 27 4.2 Impact expected from the industrial application of SOMMACT outcomes ............................................. 28 4.3 Socio-economic impact ........................................................................................................................... 28 4.4 Environmental impact ............................................................................................................................. 28 4.5 Dissemination activities ........................................................................................................................... 28 4.5.1 Scientific dissemination ............................................................................................................... 28 4.5.2 Website ....................................................................................................................................... 29 4.5.3 Newsletter ................................................................................................................................... 29 4.5.4 Leaflet and Roll-Up ..................................................................................................................... 29 4.5.5 Articles on technical magazines .................................................................................................. 29 4.5.6 Workshops and Seminars ........................................................................................................... 31 4.5.7 Trade Fairs .................................................................................................................................. 32 4.5.8 Press conferences ...................................................................................................................... 34 4.5.9 Press ........................................................................................................................................... 35 4.5.10 Web TV ....................................................................................................................................... 35 5 Contacts ......................................................................................................................................... 36 6 Use and dissemination of foreground ............................................................................................ 37 6.1 Section A (public) .................................................................................................................................... 37 6.1.1 Scientific dissemination ............................................................................................................... 37 6.1.2 Dissemination to target audiences .............................................................................................. 37 6.2 Section B – Exploitable foreground – PUBLIC ....................................................................................... 39 6.2.1 Patent applications ...................................................................................................................... 39 File:SOMMACT_Final_Report.docx Page 2 of 52 SOMMACT Self Optimising Measuring MAChine Tools CP- FP 229112-2 Final publishable summary report PROJECT FINAL REPORT 6.2.2 Description of exploitable results ................................................................................................ 40 6.2.3 IPR and exploitation claims ......................................................................................................... 50 7 Report on societal implications ...................................................................................................... 52 8 Final report on the distribution of the European Union financial contribution ................................. 52 File:SOMMACT_Final_Report.docx Page 3 of 52 SOMMACT Self Optimising Measuring MAChine Tools CP- FP 229112-2 Final publishable summary report PROJECT FINAL REPORT 1 Executive summary SOMMACT develops and validates an innovative production hardware and control system founded on understanding, evaluating and controlling large machine tools production performances. Small and single batch production, particularly for large (some cubic metres), heavy (several tons), and complex workpieces, is still a challenge for ma- chine tools users (see Figure 1.1). To achieve high product quality, timely QC (Quality Control)-production loops are required, which are inefficient and expensive. The organisation and sequencing is also difficult be- cause the process performance practical knowledge is almost unavailable. As a consequence, this type of production is still affected by inefficiencies and waste (energy, raw material and time). SOMMACT approaches these issues by the detec- Figure 1.1 – The problems to be solved tion (in-process embedded traceable measure- ments) and compensation (adaptive control and self-learning) of geometrical effects of varying exter- nal and internal quantities, such as temperature gradients and workpiece mass (see Figure 1.2). The SOMMACT vision is based on three pillars: 1. A new metrological concept to en- hance the measuring capabilities of machine tools, to monitor their geomet- rical deformations reliably and to in- spect machined parts characteristics traceably. 2. Enhanced sensor systems, measuring the 6 degrees of freedom (dof) of each machine component, and a control system integrating machine and work- piece data with environment and load conditions, and adapting machining accordingly. 3. A self-learning model