Red Bull Technology makes machine tools more accurate with first-in-UK use of Heidenhain KinematicsComp system
1 min read
Red Bull Technology – the manufacturing power behind the Red Bull Racing Formula One team - has become the first UK user of Heidenhain KinematicsComp technology, which supports improved machining accuracy. Improvements of between 2.5 and five times have been achieved, with significant investment in new machinery avoided.
"Manufacturing every component within microns helps to shave split seconds off lap times," explains Red Bull Technology production engineer, Mike Hughes.
"So, if we can improve machining accuracies to meet ever-stringent design specifications – and achieve reduced production times in the bargain - then it can only mean more accurate and streamlined manufacturing, delivering a car that can potentially be even more effective on the track.
"That strategy," he emphasises, "applies to every component produced by the team - including the carbon fibre chassis that is produced from moulds taken from male patterns that are machined on multi-axis CNC routers.
"Because the accuracy of the finished form ultimately depends on the accuracy of the machines, we need to ensure the geometric accuracy of the machines is as true as possible to original design specification.
"We knew there were inherent inaccuracies with the machine tools, as with any large complex mechanism. We therefore decided to determine – and correct – any axis positioning, straightness (in two directions perpendicular to the axes) and angular error, including roll, pitch and yaw, as well as any rotary error and axis misalignment.
"Our capex guidelines are constrained and, although we did initially consider buying a new 5-axis machine for pattern making (even though one of the required capacity would have required a very significant investment), we decided to take an alternative innovative approach, making full use of what we already have."
The company's relevant 5-axis machining centres are fitted with Heidenhain controls systems and in discussing its concerns with Heidenhain, the CNC specialist came up with a solution in the form of its KinematicsComp routines.
KinematicsComp can error model 43 parameters on a 5-axis machine tool, but Red Bull Technology mapped 21 errors for the linear axes, using an Etalon LaserTracer tracking laser interferometer, and compensated for these errors.
"The result," says Mr Hughes, "was that the KinematicsComp routines provided accuracy improvements in the order of 2.5-5 times!"
Two machines underwent the KinematicsComp treatment; one having its iTNC 530 CNC upgraded (slight updating to its hardware/RAM), and another having a new iTNC 530 retrofitted.
The KinematicsCom routines will now be used annually to recalibrate the machines.
