The presentation outlines a solution strategy for how a digital twin of a milling machine is solving mechatronic challenges. To improve cycle times, accuracy, and addressing vibration problems a holistic system simulation serves as the basis for optimization. The efficient modeling of the real system behavior with flexibilities, contacts, gaps, friction, nonlinearities in the drives (incl. saturation effects of motors), power electronics in combination with the control system is the basis for efficient controller design and optimization of the control parameters. The dynamic interaction of multiple system components combining 3D finite elements analysis multi-body dynamics and control system helps avoiding Tracking-, drag-, positioning errors rebound, and accumulation effects.  

To support the use of simulation tools in this endeavor, ABB in Spain enlisted the help of Altair ProductDesign's regional team, thanks to the company's experience in utilizing simulation tools to solve engineering challenges in the robotics industry. The project centered on improving the fatigue performance of a Twin Robot Xbar (TRX), one of ABB’s robotic part transfer systems that moves components between manufacturing stations.

The need to design more complex industrial machinery on shorter timelines means that companies ask engineers to do more with far less.

Chad Jackson, CEO of Lifecycle Insights, describes the digital approach to industrial machinery design and explains strategies leveraging Simulation, Data Science and High-Performance Computing. He shows how companies creating equipment that increases cycle speed and improves yields in this technical report.

The E-Book covers the following topics:

• THE DEVELOPMENT CHALLENGE OF INDUSTRIAL MACHINERY
• ADDRESSING STRUCTURAL STRESS AND STIFFNESS
• ARCHITECTING AND VALIDATING SYSTEMS DESIGN
• SELECTING THE RIGHT ACTUATION COMPONENTS
• MITIGATING VIBRATION AND EXCITATION
• PLANNING AND VALIDATING CONTROLS DESIGN
• STREAMLINING COMMISSIONING
• MONITORING THROUGH FIELD DATA
• RECAP AND CONCLUSIONS

In a joint project MX3D, ABB, and Altair demonstrated how a 3D printed robot can be improved by using a digital twin process to achieve more precise positioning.