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The Fraunhofer Institute for Manufacturing Technology and Advanced Materials (Fraunhofer IFAM, Stade, Germany) announces the development of a novel robotic machining tool that improves the dynamics and precision of industrial robots, combining intelligent, model-based control strategies with
innovative drive technologies and an optimized mechanical structure.

The machine tool robot (MTC) aims to close the gap between classic industrial robots and machine tools. It can be used for a wide range of applications. In combination with a linear axis, the spectrum ranges from aerospace machining tasks such as fiber-reinforced composite structures and aluminum alloys to the machining of harder materials, such as steel or titanium which are used, for example, in rail, commercial vehicle and shipbuilding, as well as in the energy sector. 

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MTC’s stand-out features are its ability to compensate for dynamic errors and effectively damp vibrations, thus improving path accuracy, even at high feed rates and during complex path movements. Optimized disturbance rejection, which ensures constant precision even with highly dynamic process forces, enables machining with higher material removal rates as well as the ability to operate with higher jerk settings, both of which Fraunhofer IFAM says lead to a significant increase in productivity.

In addition, MTC combines serial articulated arm kinematics with a linear axis, improving upon large-gantry machines and other traditional industrial processing systems. The small mounting space and linear axis’ modular design make the system highly flexible. Moreover, the use of two preloaded rack-and-pinion drives compensates for reversal effects and achieves a sufficiently high drive stiffness of the linear axis carriage for path-accurate robot processes. Due to the axis’ high structural rigidity, the influences on the robot’s accuracy are low despite the large lever arms to the load application point.

A software application for model-based calibration developed at Fraunhofer IFAM, CaliRob, opens up a complementary technology for increasing precision. A key element of this application is an extensive mathematical model that includes more than 200 parameters to describe robot kinematics on a linear axis, avoiding the individual deviations a traditional robot may exhibit.

Next steps include testing the new robot system together with R&D partners autonox Robotics GmbH as well as Siemens AG in demanding industrial
applications in order to further advance the MTC’s potential.