HEXAMOVE ...innovative 6DOF drive technology Test machines

HEXAMOVE
...innovative 6DOF drive technology
The force of innovation and 50 years
of experience
Test machines ...
Robot systems / Installation technology...
Simulation...
Entertainment...
50 years of experience in hydraulic drive technology
and a great deal of innovative drive enable us to efficiently develop tailor-made solutions for your problems. In doing this, our engineering team integrates
hydraulics, servo-technology, electronics and software,
and develops high quality products and systems individually tailored to our customers’ needs.
Our innovative drive is particularly well illustrated in the
Hexamove product series. The 6DOF platforms have
proved their worth in a large number of applications,
such as test bench construction, robotic systems and installation technology, simulation technology or the entertainment sector. In order to be able to develop
interesting solutions for your special applications at interesting costs, we have grouped the necessary technological areas into various modules, from which new
systems can be set up in the shortest possible time.
Tel. +41 (0)41 444 12 00
Fax: +41 (0)41 444 12 01
EMail:ohe@hagenbuch.ch
Web: www.hagenbuch.ch
www.ohe.ch
V13/D/200704
Rischring 1 / CH-6030 Ebikon
Schweiz
... Hexamove: Drive concept for
parallel kinematics
The Hexamove System is an open drive concept for kinematic structures
that is based on parallel kinematics. This usually means hexapods, in
which two platforms are fundamentally connected together through 6
drives. The classical variants of hexapods have a symmetrical arrangement of the drives. Depending on the task being tackled, it can, however,
be useful to try out unconventional, and sometimes surprising, arrangements of the drives. As a rule, structures with 6 drives have six degrees of
freedom (6DOF = 6 degrees of freedom), which means that
the platform moves in all spatial directions and can be rotated around all main axes.
The expression Parallel Kinematics is, however, also used
for drive systems in which, for example, only three or even
two drives connect two platforms in parallel. In structures of
this kind, certain degrees of freedom are determined by a
suitable construction.
The Hexamove System is an open concept for the control
and regulation of many different parallel kinematic structures. The optimal coordination of high quality drives, efficient electronic controllers and user-friendly software
opens up a wide field of applications, and allow the advantages of parallel
kinematics to be used to their full effect.
... Mechanics
One of the main advantages of the concepts lies in the favourable ratio of
moving inherent mass to useful load. This makes the highest dynamism and
precision possible. In order to be able to make full use of these characteristics, all moving parts are optimised in weight.
To ensure simple servicing, the structure is modularised. Bearing parts,
drives, frames etc., can be simply replaced and can then be repaired. In this
way, the costs for complicated service work are reduced.
Hexamove test machines...
Friction connection/ Path control...
Hexamove test machines with friction connection clamp the test object between the upper and lower frame. Typical applications are individual components or modules that are to be subjected to movements in 6 degrees of
freedom.
Highly dynamic Real-Motion simulator for
vehicle components
The Hexamove system is equipped with a special
workpiece receptacle on the upper and lower
platform, so that the compensator elements of
vehicle exhaust systems can be clamped in place. The test machine then runs Drive Files, which
have been previously measured on the real vehicle. In order to create test conditions that are as
realistic as possible, the components being tested are heated up to 900 degrees.
Accelerations:
4 g permanent loading
25 g peak vales
Frequency range: < 200 Hz
Accuracy:
0.01 mm
Regulation:
digital, 2 kHz, decoupling,
acceleration sensors
Path measurement digital absolute
system:
(no reference run)
Drive system:
Hydraulic servo-drives
Pressure supply:
up to 210 bar
Pump capacity depending on
application
Installation position: any
Maximum forces: 15 tonne
... Control technology / electronics
A special feature here is that the Drive Files are optimised in relation to the
acceleration. In this way, the installation can be protected from overloads,
and program sequences with little movement can be compressed in order
to reduce the test time. The accelerations will be optimised within a limit
range through the dynamic scaling of the time axis.
In addition to the Drive Files, mathematical movement functions also support the wider area of the engineering process, such as the search for resonant frequencies or the behaviour of test objects with certain excursions.
The introduction of different coordinate systems makes the system very flexible. Rotation and test points can be simply placed in the work piece so
that the platform can travel along a circular path in space when turning.
The Hexamove System can be built in almost any size. Clamping consoles
are matched to the test objects.
Hexamove Test machines...
Power regulation / Power control /
Power measurement...
Hexamove Test Machines with friction contact clamp the test object between the upper and lower frame. Typical applications are individual components or modules that are to be subjected to movements in 6 degrees of
freedom. The Hexamove System can be built in almost any size, and the
clamping consoles are matched to the test objects.
The heart of the Hexamove systems is a very fast processor with its own
multi-tasking operating system. The Hexamove core for the control and regulation of the drives runs on this master computer as its own machine controller. The software for the configuration, control and visualisation runs on
a PC with a Windows operating system, and the Master has an Ethernet interface and its own IP address. In this way, it is possible to communicate
with servers or other visualisation applications in addition to its own operating PC.
A bus system on the basis of fibre-optics connects the master with any number of interface modules for the input and output of many diverse signals.
The speed of the bus system exceeds that of most conventional PLC bus
systems by far, and is thereby predestined for use in demanding control tasks.
An important function of the Hexamove systems is provided by the Drive
Files. These are movement programs as found in machine tools, which can
be traced very precisely by the system. With the Drive Files, the degrees
of freedom can be individually amplified and be switched on or off. The process time can also be changed in order to run Drive Files in slow-motion or
at accelerated rates.
The measurement of the force takes place directly on the component, or all
the drives can be equipped with load cells. In the case of forces related to
the axes, the Master converts these into Cartesian forces in relation to the
component. The Drive File editor is thereby a comprehensive software tool
for the recording and analysis of the measured data.
Force regulation on rubber shock-absorber elements on rail vehicles
The illustration shows a test facility for rubber
shock-absorber elements, in which stiffness characteristics are recorded and service life investigations are carried out.
All drives are fitted with load cells.
Depending on the component, either a direct power control or an indirect
adaptive power control is recommended. In the case of the indirect power
control, the movements of the system will be readjusted so that the forces
measured on the component follow the desired set-value curve.
...Hexamove Test machines
Hexamove Drive-File-Editor...
...Shaker applications
In Shaker applications, the test object (an individual component, modules,
complete products) is clamped onto the moving platform and subjected to
vibrations of very different kinds. There are various possibilities for the programming of the vibrations. Curves of any kind can be pre-defined through
Drive Files, whereby these can also be based on data measured in real
processes (e.g., vehicles). Another application that is frequently used is sinusoidal oscillation. This can be directly programmed for all 6 degrees of
freedom, whereby several frequency portions can be superimposed on one
another for each degree of freedom. Additional functions are available for
noise and sweep runs.
In the case of very high requirements, the system can be combined with
specialised control systems, which further improve the signal quality. Interfaces are available for communication with various systems.
... Hexamove Control-Studio
The Hexamove Control Studio is a Windows application for the visualisation of the operational status of the Hexamove system. The current positions, forces, etc., are shown in real time. The application allows various
programs, functions and movements to be started in the same way as in a
machine tool, while messages from the Hexamove core will be displayed
and protocolled.
Lorry mirror systems on the test bench
...Analog interface
As an option, the Hexamove controller can be supplemented with additional analog inputs (16-bit), which will be interpreted as path excursions in
the 6 degrees of freedom. This operating mode also offers a wide range of
setting possibilities, such as speed limitations, scaling, switching degrees
of freedom on and off, and so on. In the case of large amplitudes, there is
the possibility of defining additional analog inputs for the fine signal range,
which will be added together and thereby guarantee a better signal-to-noise ratio.
Export of Hexamove Drive Files
Export of individual curves in the ASCII format
Import of Drive Files or measured data in the ASCII format (CSV)
Generation of curves according to mathematical functions
Generation of sweep functions
Modification of curves with mathematical functions
Spectrum / Filter functions
Editing of curves
Insertion of BSplines into curves
Integration of the complete Hexamove measured data registration
Video integration for motion programming
A typical shaker application: a leading manufacturer of lorry and coach mirror systems relies on
the flexibility of the 6DOF Hexamove system for
testing mirror systems. Under sinusoidal loading
or drive files, the complex mirror systems, including their servomotors and electronics, must prove their quality under long-term tests. A
particularly interesting fact here is that even if all
the 6 degrees of freedom are not used, system
costs are still lowered, as the set-up times can
then be reduced.
Optimizer ...
The software offers a wide range of possibilities for system settings and system diagnosis. Various Drive Files can be grouped together in lists for automatic test sequences, whereby every step can be configured separately.
An in-built player is available for digital videos, with which the system synchronises the movement to the time code.
Loading of the complete configuration after the system start
Presentation of the positions and forces
Driving to positions
Generation of Drive File lists and starting of test sequences
Video synchronisation
Starting a movement on the basis of mathematical functions
„Toolbox“ for system diagnosis
Control and selection of all available system modes
Starting of robot sequences
Configuration of network and analog interfaces
The Hexamove Drive File Editor is a stand-alone software for the processing and editing of Drive Files, for the generation of Drive Files and for the
analysis of the measured data. Measurements can be imported from any
source for the generation of the Drive Files. In addition to external sources,
the Drive File Editor also supports the comprehensive measurement data
registration package of the Hexamove System. Different mathematical
functions make possible the generation of defined curves. By means of the
editing functions, the Drive Files can be modified with, for example, BSplines, which is of particular interest for the entertainment sector. The Drive
File Editor makes its own player available for exact synchronisation with digital videos. Filter and spectrum functions support the analysis of measured data in the technical sector.
Target-Drive-File
Optimizer
Virtual
Drive-File
Effective
signal run
Hexamove System for towing channels …
The illustrated hexapod is suspended from above
and carries out the movements of the ship. Unlike
traditional test methods, it is not the water surface
that is moved (waves), but the ship model itself.
During the movements, an integrated measurement registration system records the forces on
the model. The interpretation of this data then allows conclusions to be drawn regarding the flow
characteristics of the body geometry.
The high level of flexibility of the Hexamove concept, as well as the adaptability of the control system to own applications, works particularly well
here. By means of communication with other control units, the complete towing channel can be fully automated.
Analysis of Drive Files
Single and multi-axis systems
Optimisation of control accuracy for amplitude,
phase and cornering
Full integration of the Hexamove kinematics
Analysis of control errors
Project can be saved with optimisation
Scaling possibilities
No hardware necessary /full software solutions
Simple integration using DLL
Source code templates: C++, C#
Wide range of adaptation possibilities
The Optimizer is a stand-alone software for the optimisation of control processes, and supplements the range of products around the Hexamove System. The software compares the Drive File with the data that was actually
measured, and generates a virtual Drive File from it. This can be continuously adapted until the measured values come as close as possible to
the target Drive File.
In doing this, it is not essential that the physical units of the target Drive File
and the virtual Drive File are identical. If force sequences as used as a template, the Optimizer generates a virtual path sequence, so that the measured force sequences correspond to the target Drive File. This permanent
adjustment is thereby particularly interesting for test sequences in which
the test object becomes plastically deformed during the trial.
The Optimizer controls any number of channels in parallel. For 6DOF-applications, the complete hexapod kinematics (backwards and forwards) is
integrated into the tool.
Server and Ethernet interface...
Integrated into own applications...
By means of a DLL, there is the possibility that the customer could link and
control the system in his own software. Communication with the Master
takes place over the Ethernet, whereby a small but powerful server application takes over all the network tasks in the background. Integration into inhouse applications is therefore very easy.
... Robotic systems / Positioning / Workpiece hand
Entertainment / Simulation ...
Parallel kinematics offers outstanding characteristics for robotic systems.
Large useful loads can be moved very precisely on the basis of the parallel
drives and the good ratio between inherent and transported mass.
The Hexamove core has been designed so that it can be rapidly adapted
to any parallel kinematics structure. Depending on the application, very
special geometries can also be realised in this way. The example of Airbus
(see right) illustrates a concept which is only 600 mm high in its retracted
position, but which can reach a height of more than 3000 mm when extended. Our services include providing you with support in the design and concept, as well as the calculation and simulation of working spaces.
The particular strengths of the system are the consistent implementation of
coordinate systems and the large number of controller functions. Sequences that are largely automatic can thereby also be realised.
In the case of large systems with high payloads, attention will have to be
paid to the subject of vibration. The controller therefore takes forces and
vibration behaviour into account, and, where necessary, deadens any of
these that become active in order to avoid a build-up.
In order to be able to make use of its full functionality, the system must be
optimally integrated into the working environment. A large number of interfaces facilitate this work.
The Hexamove Systems open up a wide field of uses and exciting applications for the entertainment sector. The particular strength of OHE here lies
in the customer-specific implementation of the projects. The complete
technology has been developed from our own resources, so that a solution
can be offered for almost all wishes.
For cost reasons, simple analog path measuring systems are used for simpler platforms. The electronics integrated into the cylinder combines the
measurement system electronics, the power stage for the proportional valve and the digital controller.
Difficult tasks sometimes require new and unconventional solutions. Airbus wanted to pioneer new
directions in the installation of the undercarriage
of the new A380. In order to do this, the Hexamove System had to be designed in such a way
that it would be no more than 600 mm high when
retracted, could carry loads of 10 tonne and could
position these accurately to 0.01 mm in a working
space of several metres. Fully expanded, the unit
reaches the respectable height of 3.6 metres.
with kindly authorization ILL, France
The undercarriages themselves have a height of
several metres. For this reason, the flexible concept for the integration of different coordinate systems proved its value in particular. When
installing the bearings, the Hexapod drives according to a circular path around the installation point,
Running programs for robotic systems
Storage of automatic sequences in Flash PROM
Recording of paths and the possibility of running
backwards
Interfaces for operator panels
Redundant path and angle measurement for safety-critical
applications
Choice of hydraulic or electrical drive concepts
Interface to the Siemens controller (other
manufacturers on request)
Active dampening of vibrations in large structures
Several workpiece coordinate systems can be stored
Comprehensive integration of coordinate systems for workpieces,
zero points, clamping points, etc.
Optional force measurement via pressure sensors or load cells
Determination of the useful load
Overload shutdown in case of collisions
The integration into the Hexamove controller takes place via the interface
module on the platform, while a very fast bus system on the basis of fibre
optics reduces the cost of the installation and links all the platforms to a Master. The movements can be separately processed for each platform (e.g.,
intensity of the motion).
Airbus A380: Installation of
undercarriages
High-precision positioning of workpieces
in neutron beams
The „X-raying“ of workpieces using neutron beams opens up a fascinating range of possibilities
in material research.
The Hexamove holds workpieces with a weight of
up to 800 kg and positions them in the neutron
beam with high precision. A network interface
makes it possible to easily integrate the system
into the overall system.
In the meantime, OHE hydraulics and control technology has proved its
worth worldwide in many installations, and has shown its reliability. These
include well-known installations such as the „Back to the Future“ ride in the
Universal Studios in Florida, Los Angeles and Japan, or the popular Experience Cinema in the Futuroscope in Poitier, France.
Motion cinema total solutions
An example of a total solution for a Motion Cinema
can be seen in Nuremberg in the Cinecitta. The
operator placed high requirements on automation
and reliability, so that an individual customer solution has now been realised with the Hexamove
concept.
The controller automatically loads the motion program matching the selected film, and synchronises the image and the movement. Unoccupied
platforms are not moved. A further special feature
is the operating button on the seat, which allows
the viewer to select the intensity of the movement
himself.
Full-automation of cinemas and entertainment
installations
Loading of a motion program according to stipulations from master
controllers
Optional SMPTE time-code reader
Integration of digital videos
Individual support of up to 32 platforms
Switch off of non-occupied platforms in cinema
installations
Support of digital videos
Simple integration into master systems
Monitoring via network