Real time simulation approach for the machine tool design and error compensation

In this paper a model reduction method is presented that enables the implementation and application of complex simulation models in the operating phase of machine tool control systems. Therefore, a methodology is introduced to design and develop holistic machine models, allow an exchange of simulation data, and a further reduction of the engineered models for a use in control systems. Exemplarily, the reduction of a machine model is demonstrated on the dynamic machine tool behavior. The reduction method bases on the Craig-Bampton approach. To enable the simulation of linear movements with the Craig-Bampton method, an extension for linear guides is presented and validated with the help of a 3-axis machine structure. The achieved results are compared with simulation results of a complex Finite-Element-Analysis for the dynamic machine response and a flexible multi body simulation for the dynamic positioning behavior.