How did DAMRC achieve proof-of-concept?
The Danish Advanced Manufacturing Research Center (DAMRC) successfully combines high-speed spindle operation with high-precision position control for robotic machining. Discover here, how Danfoss helped DAMRC expand the capabilities of its robotic machining setup for new manufacturing applications
DENMARK: DAMRC is a research organization dedicated to advancing manufacturing technology. Through applied research, DAMRC works to enhance productivity in the Danish manufacturing industry and bridge the gap between academic institutions and industry. One of its core research areas is robotic machining, where DAMRC develops and validates technologies that can support wider industrial adoption.
As part of its work with robotic machining, DAMRC tests different applications for proof-of-concept purposes. Robots offer a degree of flexibility in material removal which is unachievable in traditional CNC machining. They provide a large workspace in relation to their cost, can reach complex geometries from multiple orientations, and can easily be adapted to different components and processes. They can also be used in the field. This makes them particularly attractive for machining large parts and complex shapes.
The challenge: Combining high-speed operation with position control
For its robotic machining setup, DAMRC needed a drive capable of running a spindle at frequencies of up to 900 Hz. High-speed operation is particularly relevant in robotic machining, where the lower structural stiffness of industrial robot arms can create resonance challenges at lower spindle speeds.
A spindle frequency of up to 900 Hz is an unusually high requirement for an industrial drive application, making high-speed capability essential for the setup.
At the same time, the drive had to support two different functions. During machining operations, speed control was needed to regulate the spindle speed. When changing tools, position control was required to orient and index the spindle to a specific angular position for automatic tool changes.
DAMRC therefore needed a drive capable of combining high-speed spindle operation with position control.
The solution: High-speed iC7-Automation with Motion functionality
To meet the application requirements, Danfoss provided an iC7-Automation drive capable of combining high-speed operation and position control in a single drive.
The solution was implemented in several stages. These included electrical design, PROFINET integration between the robot, PLC, and drive, safety configuration, installation, and testing.
In a second stage, Motion OS701 functionality was implemented, enabling position sensing through the drive. This allows the spindle to operate in speed control during machining and switch to position control when required, without stopping and restarting in a different operating mode. Position control enables accurate spindle positioning at zero or very low speed for automatic tool changes.
“The main challenge in our application was the need to combine two very different operating conditions in a single system: high-speed spindle rotation during machining, and high accuracy at low speed or standstill, during tool change or tapping process. The iC7-Automation drive enables us to manage both operating conditions with a single drive”
– Giuliano Carrillo, Team Manager Robot Machining at DAMRC
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The MyDrive® Insight software tool further supports the setup by enabling DAMRC to monitor drive and process parameters in real time and record data from the application.
Beyond the product and software, Danfoss worked with DAMRC throughout the project, from identifying the right drive solution to configuring and integrating it into the overall setup. As new requirements emerged, the team continued to help adapt and modify the solution. This included guidance on certification requirements for the high-speed application, drive selection, and PLC integration.
DAMRC highlighted the rapid response, application flexibility, and outstanding customer service and technical support, with the overall collaboration described as among the best they have experienced in the field.
“Danfoss’ contribution went far beyond supplying the hardware. From a technical perspective, I especially valued their ability to understand an unusual application and adapt the solution accordingly. From a personal perspective, I appreciated their availability, responsiveness, and willingness to work together as project partners.”
The outcome: New flexibility for Danish manufacturers
With the Danfoss solution in place, DAMRC now has a reliable system that provides greater control over spindle parameters. According to DAMRC, the system is performing very well and offers the flexibility needed for different robotic machining setups.
Real-time monitoring and data recording through the MyDrive® Insight software tool give DAMRC greater visibility into drive and process performance. This allows the team to understand the behavior of the complete system, make adjustments efficiently, adapt the configuration as new project requirements emerge, and share relevant process information with customers.
DAMRC is already planning to apply iC7 precision control in another setup, where a rotary table will position workpieces between a welding robot and a material-removal robot.
For DAMRC, the setup can be used for proof-of-concept work across robotic machining applications. This allows Danish manufacturing companies to test and validate the limits of high-speed robotic machining before investing significant time and money in full-scale implementation. This reduces the technical and financial risks associated with adopting a new manufacturing solution on industrial scale.
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