From the economic point of view, rising the output rate of processing machines is a key requirement. Thereby, particular demands are to be met, i.e., product quality, process stability, energy consumption, impact of surroundings, or safety at work. Rising the output rate is limited, if only one of these demands can not longer be met. In this paper, a novel control approach is presented that allows to change the executed motion profile due to the actual output rate. Increasing the machine’s performance is evaluated on experimental results. Unused potentials of servo drives are opened up to generate highly dynamic multi-axis motions in processing machines.

The subject of this splitted article is the commissioning of a new application that may be part of a processing machine. At the example of the intermittent transport of small sized goods, for example, chocolate bars, ideas for increasing the maximum machine performance are discussed. Therefore, optimal process motion profiles are synthesised with the help of a computer simulation. In the first part of the paper, the modelling of the process was shown. This second part focusses on implementing the simulated motion approaches on an experimental test rig, whereby the new motion approach is compared to the conventional approach. Hence, the increasing of the performance can be proven. Eventually, possibilities for an online process control are observed which are necessary to prevent unstable process conditions.

The subject of this splitted article is the commissioning of a new application that may be part of a processing machine. Considering the example of the intermittent transport of small-sized goods, for example, chocolate bars, ideas for increasing the maximum performance are discussed. Starting from an analysis, disadvantages of a conventional motion approach are discussed, and thus, a new motion approach is presented. For realising this new motion approach, a virtual process model has to be built, which is the subject of this article. Therefore, the real process has to be abstracted, so only the main elements take attention in the modelling process. Following, important model parameters are determined and verified using virtual experiments. This finally leads to the possibility to calculate useful operating speed–dependent trajectories using the process model.

Kurzfassung: Eine Möglichkeit zur Erhöhung der Produktausbringung an Verarbeitungsmaschinen ist die Steigerung der Arbeitstaktrate. Die maximal erreichbare Taktrate ist dabei durch Anforderungen begrenzt, die aus Prozess, Maschine oder Umwelt resultieren. Zur Verschiebung dieser Grenzen bieten moderne Servoantriebe Potenziale, die bisher oftmals ungenutzt sind. Im ersten Teil des Beitrags wurde ein Lösungsansatz zur Erschließung dieser Potenziale vorgestellt. Im vorliegenden Artikel werden anhand experimenteller Untersuchungen Vorteile und Grenzen des Ansatzes dargestellt und diskutiert.

Kurzfassung: Eine Möglichkeit zur Erhöhung der Produktausbringung an Verarbeitungsmaschinen ist die Steigerung der Arbeitstaktrate. Die maximal erreichbare Taktrate ist dabei durch Anforderungen begrenzt, die aus Prozess, Maschine oder Umwelt resultieren. Zur Verschiebung dieser Grenzen bieten moderne Servoantriebe Potenziale, die bisher oftmals ungenutzt sind. Im ersten Teil dieses zweiteiligen Beitrags wird das Problemfeld erörtert und ein Ansatz zur Erschließung dieser Potenziale vorgestellt. Im zweiten Teil werden anhand experimenteller Untersuchungen an repräsentativen Verarbeitungsprozessen Vorteile und Grenzen des Ansatzes dargestellt und diskutiert.

For the hot-pressing of thermoplastic textile-reinforced composite spacer modules textile performs are needed. The Collaborative Research Centre SFB 639 at TU Dresden develops a process chain for the near-net-shape weaving of spacer performs based on hybrid yarns. A new take-up-motion, cutting and storing system is required for a fibre-sparing weaving process. The design of this system has been described in the first part of this paper. The second part begins with the development of a simulation model for the prediction of the dynamic interaction between weaving machine, take-up-motion system and thread system. Subsequently the design of the controller – based on the functional configuration of the system – is described. The description of an emulator for PLC-tests follows at the end of the paper.