ISSN1068-798X,RussianEngineeringResearch,2008,Vol.28,No.1,pp.7478.AllertonPress,Inc.,2008.OriginalRussianTextR.G.Kudoyarov,E.M.Durko,D.V.Ivanov,2007,publishedinSTIN,2007,No.10,pp.1621.74Thedevelopmentofmanufacturingentailsimprov-ingproductperformanceanddependssignificantlyonthecapabilitiesandqualityofthemachine-toolemployed.Inthiscontext,itispromisingtousemecha-tronicmachine-toolsystems,inwhichmanufacturingconsistsofcontrollableprocesses.Inmachiningblanks,inpractice,itisnecessarytotakeaccountofprocessesoccurringinmachine-tooldrives,thestateofthesup-portingsystem,andphysicalphenomenaaccompany-ingthecuttingprocess.Inordertoimprovemanufacturingefficiency,meth-odsofdesigningmechatronicmachinetoolsmustberefined.Modulardesignprinciplesarewidelyusedtodayincreatingmachinetools.Atechnologicalmoduleisastructuralunitrequiredtoperformshapingoperations1.Atechnologicalorproductionmoduleismoregenerallyacomponentofautomatedsystemsorpro-ductionlines.Astructuralmoduleisacommonunit(subsystem,element)ofthemachinetool,whichmaybeusedautonomouslyorincombinationwithothermodules.Insystemsanalysis,amoduleisunderstoodasagroupofelementsofthesystemdescribedbyinputsandoutputsandcharacterizedbyacertainintegrity2.Theuseofthisconceptallowsthemechatronicmachine-toolsystemtoberegardedasconsistingofanumberofsubsystemsinfunctionalandstructuraldesign.Amechatronicmachine-toolmoduleconsistsofamechatronicdevicethatisfunctionallyandstructur-allyindependentandperformscontrollableexecutivemotioninmanufacturing.Thebasicfunctionofthemechatronicmachine-toolmoduleinthemachine-toolsystemistoensuretherequiredmachiningconditionsorparametersoftheexecutivemotioninordertocreateparticulartechno-logicalconditionsandtoundertakediagnosticsandmonitoring.Thedefinitionofamechatronicmachine-toolmodulepresentedhereisconsistentwiththecon-ceptofakinematicgroupofamachinetool3andtakesaccountofthecapabilitiesofmodernelectricdrivesandcontroldevices.Thekinematicgroupensuringcomplexexecutivemotionmaybeformedbymeansoftwoormoresimplemodulesorrepresentedasacombinedmodule,withinwhichthecomponentsofthemotionarematchedbyacontrolsystem.Inthisrespect,themechatronicmachine-toolsys-tem(ormechatronicmachinetool)isasetofmecha-tronicmachine-toolmodulesordevicesforperformingcertainfunctionsinthemanufacturingprocess,takingaccountoftherealconditions.Acertainsequencemayexpedientlybeadoptedinthedevelopmentofmechatronicmachine-toolsystemsandmodules(Fig.1).Thetechnicalspecification(TS)inthedesignofamachinetool(orcorrespondingmechatronicmodule)mustprovideasetofinformationonthepartstobemachinedandthemanufacturingrequirements.Takingaccountofthenecessaryeffi-ciencyandreliabilityofthetechnologicalprocess(TP),therequiredmachine-toolcharacteristics(MC)areestablished.Reliabilityofthetechnologicalprocessisassumedtomeanguaranteedprovisionoftherequiredmachiningparameters.Inautomateddesign(AD)ofthetechnologicalpro-cess(operation),thegoalistorefinethemanufacturingpathofarepresentativepartanddeveloptheoperationstobeperformedbythemachinetoolunderdesign.Resultsobtainedindevelopingprospectivecontrollablemanufacturingprocessesforanalogouspartsmustbetakenintoaccounthere.Itisexpedienttodevelopthetechnologicaldocu-mentationbymeansofmoderncomputer-assisteddesignsystemsfortechnologicalprocessesandappro-priatesoftware(SolidWorks,SmarTeam,Stalker,Tekh-noPro,ADEM,PowerMill,etc.).Inestablishingthebasictechnologicalprinciples,thetypicaloperatingconditionsofthemachinetoolinthemanufactureofspecifiedpartsmustbedetermined.Modelingofthedrives,thesupportingsystem,andthecomponentsofthemachinetoolcallsforthedevel-opmentandinvestigationofsimulational,structural,anddynamicmodels,inordertodeterminetheexpecteddeviationsintherelativepositionofthetoolandblankduringproductiveandeconomicalmachine-tooloperations.DesignofMechatronicMachine-ToolEquipmentR.G.Kudoyarov,E.M.Durko,andD.V.IvanovDOI:10.3103/S1068798X08010176RUSSIANENGINEERINGRESEARCHVol.28No.12008DESIGNOFMECHATRONICMACHINE-TOOLEQUIPMENT75Onthebasisofthemodelingresults,methodsofimprovingthemachinetoolscharacteristicsaredevel-oped.Methodsofcompensatingimprecisionofthemachinetoolaredetermined；itsoperationalalgorithmsandstructurearerefined；andblockdiagramsoftheloopsintheadaptiveorsmartcontrolsystemaredevel-oped.Preliminaryautomateddesignofthemechatronicmachinetool,takingaccountofthemodelingresults,permitstheselectionofthemechatronicmodulesfromthoseavailableandthedesignofnewmodulesorthemachinetoolasawhole.Thesedevelopmentsarefor-malizedinregulatorydocumentationforeachstageofthedesign(engineeringpreparationsandthedraft,engineering,andworkingdesigns).Onthebasisofthedataobtained,themachinetoolcharacteristicsarecal-culatedandcomparedwiththespecifications.Thiscre-atesthebasisforrefiningthemachinetoolstructure,organizingthetechnologicalpreparationsforproduc-tion(TPP),andmanufacturingandtestingaprototypemachinetool.Ininvestigatingthecharacteristics,themodelsarerefined,andmethodsofimprovingthemachinetoolsabilitytoguaranteetherequiredoperationalparametersinautomatedproductionaredetermined.Whethertherequiredcharacteristicsareensuredwilllargelydependonthestructureofthemachinetool.Thefunctionalsubsystemsofthemechatronicsystemmaybedividedintofourlevels,inaccordancewiththeclassificationin4,5.Thesubsystemsateachpreviouslevelaresystemswithrespecttothesubsystemsofthesubsequentlevel(Fig.2).SubsystemsoflevelIensuretherequiredexecutivemotionandconsistofmechatronicmachine-toolmod-ules,includingbasicandauxiliarymodulesandsimpleandcombinedmodules.ThesubsystemsoflevelIIdependontheparametersoftheexecutivemotions.Analysisofthefunctionsperformedinautomatedman-ufacturingindicatesthatthesubsystemsatlevelIIareresponsibleforthestarting,stopping,andreversingofthedrivesandforensuringtherequiredspeed,displace-ment,andtrajectoryoftheexecutivemotion.ThesubsystemsoflevelIIIensuretherequiredoper-ationalandauxiliarymotion.SubsystemsoflevelIVareassociatedwiththetypesofregulatoryactions,cat-egorizedasthoseperformedinaccordancewiththeprogram,adaptiveactions,andintellectualactions.Inmechatronicmachinetools,thesubsystemsoflevelsIIIandIV,producingsmoothadaptivechangeintheaccel-erationandvelocity,areofparticularimportance.Intheanalysisofmachiningprocedures,amethodofshapingthepartmustbeestablished,aswellasthesetofexecutivemotionsandtheparticulartechnologi-caltransitions.Thesetransitions,intheformoftheoperationalalgorithmofthemechatronicmachine-toolmodule,maybeidentifiedonthebasisofoptimizationofthecuttingprocessandthemachine-tooldynamics.Forexample,itisexpedienttoadjustthecuttingspeedinthecourseofmachining,takingaccountofthecut-tingtemperature,inordertoensurehigherproductivityandaccuracyofrelativemotionofthetoolandblankandlowermachiningcost,asshownin6.Theappropriatefunctionalsubsystemsmustbecho-sentoimplementtherequiredtechnologicaltransitionsandoperationalalgorithmsofthemechatronicmachine-toolmodule4,5.Thechosensubsystemsdeterminethesensorsrequired.Onthebasisofthesedata,theblockdiagramandstructureofthenewmod-uleareselectedordeveloped.ThedesignofthesupplymoduleforamultipurposemachinetoolisillustratedinFig.3.Takingaccountofthepossibleoperationalpatternsofthemoduleandthenecessaryfunctionalsubsystems,structuralvariantsaredeveloped.TSADofTP,establishingPreliminaryADDotheMCRefinementoftheTPP,manufacturing,DotheMCobtainedManufactureInformationonthepartDeterminingthetypicalDevelopmentofSimulationofdrives,InvestigationofMCYesNoformachine-tooldesignbasictechnologicalprinciplesofmachinetoolobtainedcorrespondtothespecifications?YesNomachine-toolstructureandthecontrolalgorithmstestsofprototypecorrespondtothespecifications?ofmass-producedmachinetooltobemanufacturedandtheMC,takingaccountofmanufacturingrequirementsoperatingconditionsofthemachinetoolanditstechnicalcharacteristicsmethodsofimprovingtheMCsupportingstructure,componentsFig.1.Sequenceadoptedindevelopingmechatronicmachinetools.76RUSSIANENGINEERINGRESEARCHVol.28No.12008KUDOYAROVetal.Inthefirststage,theparametersofthemechatronicmachine-toolmodulearedeterminedsoastoensuretherequiredtotalrigidity7.Thenarefinedmodelofthesupplydriveisformed,theexpectedoperationalchar-acteristicsofthemodulearedetermined,anditsdesigniscorrected.Notethat,withdifferentmachiningconditionsinthesamemachinetool,partsofdifferentqualitymaybeobtained.Ifthespecifiedrequirementsonthequalityarenotmetforthemachiningsysteminitiallyselected,itischanged,orelsethetypeanddesignofthemoduledriveischanged,withsubsequentverification.Animportantmeansofimprovingmachiningiscor-rectionofthecontrolprogramonthebasisofsimula-tiondata,takingaccountoftherequiredreliabilityofthemodule.Indevelopingthemodelofthesupplydrive,thefol-lowingfactorsmustbetakenintoaccount:theregula-toryactiontoensuresmoothermotion；thevariationintheforcesinthecourseofoperation；andthemethodsemployedtoincreasethevibrationalstability.Notealsothat,atthebeginningofmotion,thefrictionalforcedoesnotincreaseinstantaneouslytothesteadyvalue；thereisatransientprocesswithoverregulation8.Thisaffectsthedynamiccharacteristicsofthedrive,espe-ciallywithasmalltractionalforce.Inthecalculationschemeofthesupplydrive(Fig.4),threepointmassesaretakenintoaccount:m1isthearmatureoftheelectricmotor,togetherwithpartofthedrivescrew；m2istheotherpartofthescrew；m3istheexecutiveorgan(table)thatistobemoved.AlsoinFig.4,K1andh1arethetorsionalrigidityanddamp-ingcoefficientofthearmatureandpartofthedrivescrew；K2,h2andK4,h4aretheaxialrigidityanddamp-ingcoefficientsofsectionsofthedrivescrew；K3,h3andK5,h5arethesamequantitiesfortherollerbear-ings；K6andh6arethesamequantitiesforthescrewnutjunction；K7andh7aretherigidityanddampingcoefficientforthefrictionalprocessesintheguidepieces.Thetopologicalequationsforsectionsofthemodeltaketheform(1)MAMe1Md1Mi10；=Me1Md1Me2Md2Mi2+0=Fe3Fd3FdaFfrPxFi3,=Informationonthepart,MaingoalBasicStructureofMMSCompositionCompositionCompositionofCompositionofCompositionofTargetVariationSetTypesofrequirementsontheTPandproductandfunctionsofMMScharacteristicsofMMSsubsystemsoffunctionalsubsystemsIIIIIIIVofMMSthesubsystemsensuringthemotionparametersthesubsystemsensuringparticularfeaturesofthemotionparametersthesubsystemsensuringthecontrolfunctionsfunctionsofcontrolofmotionparametersmechatronicmodulesandconsistencyofthemotionparametersFig.2.Relationbetweenthesubsystemsofthemechatronicmachine-toolsystem(MMS):IIVlevels；TP,technologicalprocess.InitialdataDevelopmentandselectionDrawingsoftheparts,DatabaseofoperationalCalculationofSelectionofthetypesDatabaseofelectricmotors,SimulationEvaluationofdriveAgreementwithNoYesRefinementofstructuraloptionsmachiningsystems,cuttingconditions,productionrequirementssystemsandalgorithmsofmechatronicmachine-toolmodulesandtheirfunctionalsubsystemstheforcesinthedriveofcomponentsandthedesignmechanisms,bearings,andguidepiecesofdesignofdrivecharacteristicsandmachiningparametersthespecifications?Fig.3.Automateddesignofamechatronicsupplymodule.RUSSIANENGINEERINGRESEARCHVol.28No.12008DESIGNOFMECHATRONICMACHINE-TOOLEQUIPMENT77whereMAusthetorqueatthemotorarmature；Me1,Md1,Mi1areelastic,dissipative,andinertialtorquesatthedrivescrew；Me2,Md2,andMi2arethesametorquesonthenutinthescrewtransmission；Fe3,Fd3,Fi3aretheelastic,dissipative,andinertialforcesontheexecutiveorgan；Fda,Ffrarethedampingandfrictionalforcesintheguidepieces；Pxistheaxialcomponentofthecut-tingforce.OnthebasisofEq.(1),wemaywritethemoregen-eraltopologicalequationwhered0isthediameterofthecircumferenceofthecentersoftheballsinthescrewtransmission；theplussigncorrespondstoaccelerationoftheexecutiveorgan,andtheminussigntodeceleration.Themodelofthesupplydriveisdevelopedasagen-eralizedstructuralsystem,whichmaybeimplementedandinvestigatedusingSimulinksoftwareintheMAT-LABsystem.Wenowconsidertheresultsofsimulatingthedriveofthemechatronicsupplymoduleofamultipurpose250Vmachinetool(producedbySterlitamakmachine-toolplant).Sinceautomaticreversalofthemotionbythedrivemayaccompanycontourmachiningofthepart,itisofgreatinteresttodeterminetheoperatingconditionsofthedriveforfastandsmoothreversingoftablemotioninthemodule.Itisfoundthatthetransientprocessdependsmainlyonthecharacterandtimeofvariationofthecontrolsig-nal,thetablemass,thedragforce,andthedampingofdrivecomponents.ThevariationintablevelocityvasafunctionofthestartingtimetsisshowninFig.5.Thepositioningaccuracyoftheexecutiveorganmayexpedientlybeincreasedbyregulationoftheacceleration,takingaccountofthechangeinvelocity.Theresultsobtainedprovidethebasisforrecommenda-tionsregardingtheimprovementinstructureofthemechatronicsupplymoduleofthe250Vmachinetoolandcontrolofitsoperation.2MAMi1Mi2()/d0Fi3FdaFfrPx0,=Refinementofthemethodofanalysisofthemachinetoolstructuretakesaccountoftheresultsin3,9.AutomatedcalculationofthesystemcomponentsisbasedonBorlandDelphi6.0softwarepermittingcom-putationoftheprecisionandpliabilityofvariouscon-figurationsoflathesandmultipurposemachinetools.Calculationofgeneralizedcharacteristicspermitsanal-ysisofthemachine-toolconfiguration.