1. Page 1 Ascending production of new machine tools Retrofitting and refurbishing of existing machine tools Replacement and renewal of outdated machine tools Large demands for new machine tools and new machine tool parts Great demand for energy, material and financial resources Great potentials to save time, energy, raw material and financial resources Increase the participation of small manufacturer in global value creation B5 - Design of Accuracy Increasing Systems for Simple Machine Tools - Motivation Upgrading and reusing of existing machine tools with minor modification of existing systems

2. Page 2 B5 - Design of Accuracy Increasing Systems for Simple Machine Tools Challenges  Comparison of outdated with modern machine tool  Implementation of a technical solution which is worth 10% of the new investment  Improvement of older machine tools with the technical progress of 10 years Higher accuracy Higher efficiency More functionality Trends towards modern machine tools FP4 4-axis CNC milling machine, DECKEL, 1986. DMU-50 3+2-axis milling machine, DECKEL MAHO, 2008.

3. B5 - Design of Accuracy Increasing Systems for Simple Machine Tools Approach DetectionCalculation Accuracy increasing systems Efficiency increasing systems Intelligence increasing systems Add-on adaptronic components Outdated machine tool Upgraded machine tool with add-on components  No exchange of main machine components (Spindle, feed drives and electronic)  Adaptability to different type of occurring disturbances  Subsequently installable on different types of milling machines  Compensation of occurred deviations Compensation Page 3

4. B5 - Design of Accuracy Increasing Systems for Simple Machine Tools Results 2014  Economical dimensions  A highly flexible add-on compensation concept has been developed.  The compensation unit can improve the machining accuracy of outdated midsize 3-axis milling machines significantly.  The costs have been estimated between 10 % to 15 % of renewal costs. The life time of compensation unit have been estimated up to 15 years.

5. B5 - Design of Accuracy Increasing Systems for Simple Machine Tools Results 2014  Ecological dimensions  Energy efficiency of outdated milling machine tools has been measured and investigated.  Weak spots and improvement strategies have been identified.  Productivity analysis of outdated milling machines has been carried out.  Different field scenarios for application of adaptronic add-on components have been investigated.  Application and field scenarios have been identified, under which the B5-concepts can be applied more sustainable.  Social dimensions  Methods, instructions and apps enables the small operator to setup and use the adaptronic component. Axis jog Standby 5 1 0 2 FP4NC milling machine kVA Ready 3 Tool change Spindle at 2000 RPM Door Coolant pump run DMU-50 milling machine Air cutting Total power demand S Air cutting parameter: Spindle speed = 1114 RPM Feed velocity = 267 mm/min Operation Comparison of required power of major components of investigated machine tools without material removal.