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Professorship for Machine Tools and Forming Technology
Control and Feedback Control Technology

Division Control and Feedback Control Technology

Control, Feedback control, Monitoring

Vision

  • competence partner for the control and feedback control of mechatronic systems in research, industry and education
  • the aim is to reduce the discrepancy between theoretical methods and industrial application of control and feedback control technology through applied research
  • expand existing competencies through diversification (machine tools, robotics, forming technology and virtual reality)

Research Focuses

Research Topics in the Division are:

  • identification of mechatronic systems (invasive and noninvasive)
  • controller design taking into account multiple criteria (robustness, limitations,…)
  • control loop performance monitoring e.g. for mechatronic systems
  • the resulting tasks such as controller design and commissioning tools, compact controller, energy-efficient operation of mechatronic axes, control of flexible structures

Target Groups

In the context of applied research projects, the division Control and Feedback Control Technology is a technology and competence partner for companies. For students, lectures in „Control and Feedback Control Engineering“, „Industrial Control Engineering,“ „Automation of Machines“ and „Applied Feedback Control Engineering“ as well as interdisciplinary student research projects, project theses and master's theses are provided.

Dr.-Ing. Holger Schlegel

Head of Division

+49 (0)371 531-32236
holger.schlegel@...
2/M115

Dipl.-Ing. Henry Kirchner

Research Associate

+49 (0)371 531-34649
henry.kirchner@...
2/M101a

M.Sc. Tien Sy Le

PhD Student


tien-sy.le@...
2/M114a

M.Sc. Manuel Norberger

Research Associate

+49 (0)371 531-36970
manuel.norberger@...
2/M114b

Dipl.-Ing. Johannes Quellmalz

Research Associate

+49 (0)371 531-37863
johannes.quellmalz@...
2/M101b

Dr.-Ing. Matthias Rehm

Research Associate

+49 (0)371 531-37447
matthias.rehm@...
2/M101b

M.Sc. Armin Schleinitz

Research Associate

+49 (0)371 531-30122
armin.schleinitz@...
2/M114b

M.Sc. Chris Schöberlein

Research Associate

+49 (0)371 531-30505
chris.schoeberlein@...
2/M114b

M.Sc. André Sewohl

Research Associate

+49 (0)371 531-33687
andre.sewohl@...
2/M114a

Ing. M.Sc. Peggy de Witt

Research Associate

+49 (0)371 531-36055
peggy.de-witt@...
2/M101a

 

Identification and Commissioning of feedback control of electromechanic axes
  • modelling and Determination of Parameters of technical systems
  • adaption of odentifikation methods for motion control right trough to industrial applicability
 
Controller design for mechatronic systems
  • taking into account diverse design criteria and extended structures
  • implementation on industrial drive systems
 
Control Loop Performance Monitoring in drives
  • Development of monitoring functionality for electromechanic axes
 
Setpooint generation
  • Path planning for systems with redundant axes
  • Motion profiles with increased energy efficiency
 
Development of automation concepts and feedback control strategies for specific issues
  • Realization of complex motion control solutions on modern control and drive hardware
  • feasibility studies / prototypical implementation of new control engineering functions on industrial control hardware
  • development of feedback control strategies to specific problems
  • determination of parameters / investigation of dynamic properties of various machine components
  • contact:
    Dr.-Ing. Holger Schlegel
References
  • „selection, optimization and exemplary controller implementation of an extended kinematics “ (Siemens AG)
  • „automatic offset calculation for the injection quantity during the serial testing of common rail injectors“ (Continental VDO Automotive AG Limbach-Oberfrohna)
  • „analysis, modeling and controller synthesis for a welding apparatus to track edges“ (BMF GmbH, Grüna)
  • „development of an intelligent DP hydraulic module“ (Siemens AG)
  • „development of functions for feedback control technology in the field of industrial control, identification, self-adjustment and optimization“ (IST GmbH Chemnitz)
 

Process safe, flexible-geometry tool and machine concept for collar forming "Secoflex"

process monitoring and control scheme
  • "Zentrales Innovationsprogramm Mittelstand"
  • advancement of collar forming process
  • process monitoring ensures quality and raises productivity
  • contact:
    Dr.-Ing. Matthias Rehm
  • duration: 11/2017 – 10/2019
  • funded by: Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF, German Federation of Industrial Research Associations)
 

Augmented Reality on Electromechanical Die Cushion ("Ziehkissen")

servo screw press
 

Smart Data Services for production systems

Smart Data Services
  • monitoring of changing characteristics (e.g. process values) during regular machine operation
  • global availability of machine and process data via Smart Data Services
  • appropriate expansion of the drive structure and its optimal parameterization
  • contact:
    M.Sc. Chris Schöberlein
    and
    M.Sc. André Sewohl
  • further research sites: Fraunhofer-Institut for Machine Tools and Forming Technology IWU and
    TU Dresden - Institute of machine tools and control engineering
  • duration: 03/2017 – 02/2020
  • funded by: European Union and Free State of Saxony
 

AMARETO – Saxon Alliance for MAterial- and Resource-Efficient TechnolOgies

Logo AMARETO
  • partner: TU Chemnitz, TU Dresden, TU Bergakademie Freiberg, Fraunhofer IWU
  • contact:
    Dr.-Ing. Matthias Rehm
  • duration: 01/2017 – 09/2020
  • funded by: European Union and Free State of Saxony
 

Comparative examination on deep-drawing with extended process cinematics

pulsating deep-drawing schematic
  • extended process cinematics enhances technological capabilities
  • fundamental research in examination of the underlying effects, e.g. at pulsating deep drawing
  • detemination of characteristic values for seizing predictivity in sheet forming simulation
  • contact:
    M.Sc. André Sewohl
  • further research site: Fraunhofer Institute for Machine Tools and Forming Technology IWU (contact: Dr.-Ing. R. Mauermann, Dipl.-Ing. Sebastian Kriechenbauer)
  • duration: 09/2015 – 04/2018
  • Funded by: Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)
 

Improved availability for large machine tools by new condition monitoring approaches

large machine tool
  • monitoring feed axes without extra sensors
  • non-invasive identification of mechanical parameters
  • control loop performance monitoring for early recognition of defects
  • contact:
    Dipl.-Ing. Johannes Quellmalz
  • further research site: Fraunhofer Institute for Machine Tools and Forming Technology IWU (contact: Dipl.-Ing. Uwe Frieß)
  • duration: 10/2015 – 03/2018
  • funded by: European Union and Free State of Saxony
 

System for thermal and mechanical feedback controlled finishing process "STUMF"

roller burnishing on a turning machine
  • "Zentrales Innovationsprogramm Mittelstand"
  • development of a sensory roller burnishing tool for process monitoring and control
  • process control by superimposed feedback force control - workpiece to workpiece
  • process monitoring and documentation of technological parameters
  • detection of defects on the tool and the workpiece
  • contact:
    Dr.-Ing. Holger Schlegel
  • further research site: Fraunhofer Institute for Machine Tools and Forming Technology IWU (contact: Dipl.-Ing. Gerhard Regel)
  • duration: 01/2015 – 12/2016
  • funded by: Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF, German Federation of Industrial Research Associations)
 

ALBATROS - Automated labeler type series with adaptable, transportable and optimized strcture

labeler construction (cutout)
  • "Zentrales Innovationsprogramm Mittelstand"
  • modular mechatronic conzept utilizng decentralized drives
  • exemplary labeler realization for debit card sized tags
  • contact:
    Dr.-Ing. Matthias Rehm
  • duration: 10/2014 – 12/2016
  • funded by: Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF, German Federation of Industrial Research Associations)
 

Feedback control structure extension for decoupled servo drives at presses

top view of servo press with motor coupling shaft unmounted
  • development and simulational check of new feedback control structures
  • implementation on insustrial motion controller solution
  • contact:
    Dipl.-Ing. Henry Kirchner
  • duration: 2014 – 2016
  • cooperation with the Fraunhofer Institute for Machine Tools and Forming Technology IWU
 

System concept for a load-optimized design of forming tools

modular load simulator in servo screw press
  • "Zentrales Innovationsprogramm Mittelstand"
  • feedback control concept for the decentralized actuation of the optimized forming tools
  • contact:
    Dipl.-Ing. Johannes Quellmalz
  • Lduration: 07/2013 – 06/2015
  • funded by: Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF, German Federation of Industrial Research Associations)
 
  • Cluster of Excellence within the Saxon Competition „Sächsische Landesexzellenzinitiative“
  • contact controller design and infrastructure machine tool:
    Dr.-Ing. Matthias Rehm
  • contact Control Loop Performance Monitoring and identification of controlled systems:
    Dipl.-Ing. Johannes Quellmalz
  • further information: Homepage eniPROD
  • duration: 2009 – 2014
  • funded by: European Union and Free State of Saxony
 

Improving dynamics and accuracy of servo screw presses by optimized feedback control

servo screw press
  • analysis of the dynmic behaviour odf the servo screw press and actual feedback control strategies
  • extension of technolgical possibilities of servo screw presses by direct positioning control
  • deiving conceptual rules and implementation at a servo screw press
  • Ansprechpartner:
    Dr.-Ing. Holger Schlegel
  • duration: 07/2012 – 03/2015
  • funded by: Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF, German Federation of Industrial Research Associations)
 

Landesinnovationspromotion

example two-dimensional search domain
  • usage of hybrid optimization methods prior to and during the realtime based feedback control of mechatronic systems
  • contact:
  • duration: 2010 – 2013
  • funded by: European Social Fund and Free State of Saxony
 

Junior Research Group „MoLeiRo“

project logo
  • joint project with the professorships of Robotic Systems, Electrical Machines and Drives, Automation Technology, Lightweight Structures and Polymer Processing of the Technische Universität Chemnitz
  • control and feedback control of individual lightweight components (robotic arms), taking into account static and dynamic path deviations (vibrations in lightweight structures) and anisotropic material properties
  • analysis of appropriate sensor signals to evaluate the deformation of flexible components and the accelerations and torques
  • contact:
  • further information: Homepage MoLeiRo
  • duration: 10/2009 – 09/2012
  • funded by: European Social Fund (ESF) and Free State of Saxony
 

Efficient Manufacturing Processes with Integrated Coating Technologies (EFFICOAT)

project logo
 

Servo forming unit OBERON

servo forming unit OBERON
  • two linear actuators with roller screw drives
  • emulation of forming forces:
    • spring modules (screw spring, elastomer)
    • cutting module
    • flexible positioning of modules e.g. to achieve eccentric load
  • sensors:
    • actuator or process forces
    • two direct position meassurement systems (calculation of tilt)
    • motor encoders
Technical specification
  • force per actuator 17,6 kN, peak >24 kN
  • maximum velocity: 127 mm/s
  • maximum stroke 150 mm
  • Siemens SIMOTION C240-2
 

Linear motor test stand

Linear motor test stand


Linear motor test stand
  • Multiaxis test stand with iron core linear motors with permanent magnet excitation
  • Modular mechanical installation:
    • With transversal axes – Gantry Principle (2 longitudinal motors + one transversal axes)
    • By tooth belt – longitudinal oppositely moving
    • electromagnetic eddy current brake for appliance of longitudinal dynamic disturbance
  • pivotable functional assembly – variation of g-force influence (0…90 degrees)
  • variation of each motors additional masses
  • equipped with the latest actuators
Technical specification
  • maximum acceleration 100 m/s2 (= 10 g)
  • maximum velocity: 120 m/min
  • maximum stroke 1000 mm (longitudinal axis) / 500 mm (transversal axes)
  • maximum additional mass: 12.5 kg / motor
  • Siemens SIMOTION D445
 

Modular leightweight robot

Modular leightweight robot
  • jointed arm kinematics with modular instalaltion:
    • leightweight beam (Carbon fiber reinforced plastic) with integrated sensor systems
    • stiff beams
    • definitely resilient arm with different sensors (strain, multiaxis acceleration, optical sensors)
  • Automated by motion conrol system for high flexibility:
    • teach in
    • variable feedback controler structures
    • koordinate transformation and path planning
  • equipped with the latest actuators
Technical specification
  • max. working radius: 840 mm
  • maximum additional mass: 1 kg
  • Siemens SIMOTION D445
 

Feed axis

feed axis test stand


feed axes test stand
  • control-oriented analysis of different movement profiles (energy efficient, highly dynamic) on the example of the ball screw drive
  • simulation of disturbance and process forces (tool engagement, cavities, HSC)
  • modular design of analysis of damping and resonance behavior subject to different ball screw drives and varied control systems
  • extensive measurement equipment (force, torque, displacement (absolute / relative), acceleration, angle, temperature) for the integration and testing of advanced control strategies
  • equipped with the latest actuators
Technical specification
  • maximum stroke: 1500 mm
  • maximum speed: 40 m/min
  • maximum load: 450 kg
  • Siemens SIMOTION D445 and SINUMERIK 840 DiSL
 

Motion control

drive train rotatory axis
  • simulation of variable loop characteristics such as friction, changeable inertia and torques
  • analysis of varying properties in terms of the controller dimensioning
  • implementation of complex solutions in modern control and drive hardware
  • flexible mechanical design
  • extensive sensor technology
 

Pneumatic servo axes

pneumatic servo axes test stand
  • two linear servo axes on the basis of pneumatic cylinders, each operated by a servo valve
  • position and force control with the option of mechanical linkage of the drives
  • emmulation of disturbance forces and certain load cases
  • extra weight for the variation of the controlled system
  • flexible, programmable, distributed control system with the option of implementing free control and monitoring algorithms
  • extensive measurement equipment (force, displacement, pressure) for integration and testing of advanced control strategies
 

Motion control

Axes setup for demonstration
  • advantage of motion control is the replacement of mechanical (gears, clutches, cam gears, cams) with mechatronic components
  • high-reach flexibility - increasing importance such as production machines
  • 3 test stands with latest control hardware and software for training
  • practical training for implementing basic functions of movement (positioning, synchronous, electric transmission, electric cam)
  • transfer of the basic functions to printing or packaging applications
 

Programmable logic control

practical course environment PLC
  • 7 workplaces equipped with the latest hardware and software for up to 21 students
  • training in IEC 61131 compliant programming languages LAD, FBD, STL, and graph
  • various test boards for the simulation of processes
    • good visualization of the programming results
    • scalable task complexity: from simple machines to complex process control systems with production data capture
 

Feedback control technology

practical course environment feedback control technology
  • 6 workplaces equipped with test and measurement boards from Leybold Didactic
  • practical training as a means of feedback control engineering knowledge
  • performing independent parameter identification and structure of control loops with different models possible
  • descriptive representation and convenient evaluation of the experiments with graphical user interface directly on the PC by Cassy-Lab

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