Annual Report Department


Quality control and total quality management



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3.6Quality control and total quality management

3.6.1GROWTH Project no. G6RD_CT-1999-00122 SEC&TEC: Static and Quasi Static Error Measurement and Compensation in Milling Machines


Partners: Fidia (I), Tekniker (E), Krypton (B), RWTH Aachen - WZL (D), K.U.Leuven-PMA (B), Correa (E), Zimmermann (D)

Objective: The joint efforts within this consortium strive to increase the precision of machine tools. This is done by targeting the geometrical deviations within the machine caused by wear and workload as well as the effect of temperature variations on the machine structure, i.e. respectively the static and quasi-static errors. Currently corrective measures rely on mathematical descriptions to estimate static and quasi-static deviations. The aim is to improve machining precision by direct error monitoring during operating conditions rather then by using error estimations. The project’s deliverables include a 6D measurement device for on-line error identification. New error-identification procedures will exploit the capabilities of modern numerical controllers and measurement devices to reduce machine down time for verification and maintenance.

Period: Feb 2000 – Jan 2003

Contact: J.-P. Kruth, L. Zhou, C. Van den Bergh

3.6.2Total Quality and Reengineering in the Department of Justice


Partners: Ministerie van Justitie, Parket van Leuven

Objective: The Prosecutions Office (Parket) of Leuven was chosen as a pilot-site to implement TQM and BPR techniques for reshaping the structure of the organisation. At the same time a performance measurement system for the main administrative processes has to be designed. The EFQM based INK-model is used as a reference for analysis and design. A new organisational framework is implemented. Several processes affecting critical success factors have been redesigned. Appropriate BPR software is introduced.

Period: Jan 2003 – Dec 2003

Contact: L. Gelders

3.7Mechatronics and robotics

3.7.1Growth Project no. G6RD_CT-1999-00122 SEC&TEC: Static and Quasi Static Error Measurement and Compensation in Milling Machines


Partners: Fidia (I), Tekniker (E), Krypton (B), RWTH Aachen - WZL (D), K.U.Leuven-PMA (B), Correa (E), Zimmermann (D)

Objective: The joint efforts within this consortium strive to increase the precision of machine tools. This is done by targeting the geometrical deviations within the machine caused by wear and workload as well as the effect of temperature variations on the machine structure, i.e. respectively the static and quasi-static errors. Currently corrective measures rely on mathematical descriptions to estimate static and quasi-static deviations. The aim is to improve machining precision by direct error monitoring during operating conditions rather then by using error estimations. The project’s deliverables include a 6D measurement device for on-line error identification. New error-identification procedures will exploit the capabilities of modern numerical controllers and measurement devices to reduce machine down time for verification and maintenance.

Period: Feb 2000 – Jan 2003

Contact: J.-P. Kruth, L. Zhou, C. Van den Bergh

3.7.2Growth Project no. 40538, Nano Grind : Realising Curved Surfaces with Optical Quality by means of Nano-Precision Grinding based on ELID technology


Partners: : K.U.Leuven-PMA (B), Cranfield University – SIMS (UK), TNO Industrial Technology (NL), Fundaçion Tekniker (E), Loh Optikmaschinen (D), Berliner Glas KgaA (D), Centro Ricerche FIAT (I), GRAVITÁS 2000 (HU)

Objective: Traditionally, most optical surfaces are produced by grinding followed by lapping (also called grinding in the optics field) and polishing. More recently some lenses were produced by moulding (typically plastic spectacle lenses and lenses for low-cost cameras) but this also required the moulds to be made in the traditional way.

Nano Grind aims at producing cheap, smooth and curved optical surfaces (in glass, ceramics or hard metal) using an innovative grinding machine tool with electrolytic in-line dressing (ELID). Nano Grind will give a significant machining cost reduction with equal specs on dimensional accuracy and surface quality. This will be realized by a faster overall production process for direct manufacturing and by offering longer standing moulds for replication. This will result in an important cost reduction for the end-user. Nano Grind will enable production of curved surfaces with average roughness value comparable to polishing. Nano Grind will also enable production of curved surfaces with a very high dimensional accuracy. Combined with the previous objective this will allow high-precision optics with high shape accuracy.



Period: Jun 2002 – May 2005

Contact: D. Reynaerts, J. Qian, P. Vleugels D. Hemschoote

3.7.3Growth project GRD1-2000-2527, MECOMAT: Mechatronic Compiler for Machine Tool Design


Partners: Samtech (B), CE.S.I. (I), K.U.Leuven-PMA (B), University of Lancaster (UK), Budapest Univ. of Tech. And Economics (HU), CNR-ITIA (I), CETIM (F), COMAU (I), HOLROYD (UK)

Objective: The main objective of the project is to develop a computer-aided design tool and methodology for the mechatronic design of machine tools, which supports both conceptual and detailed design processes. The project will develop an integrated software system for the synthesis, analysis and optimisation of machine tools following a mechatronic approach where the design of the mechanism, the mechanical structure, and the control system is performed concurrently. Seven main functional modules will be developed and integrated as follows: layout design; design of motion units; servomechanism design; mechanical modelling; mechatronic compiler; and analysis/optimisation tools.

Period: Feb 2001 – Jan 2004

Contact: H. Van Brussel, F. Al-Bender

3.7.4IUAP Project nr. P5/06: Advanced Mechatronic Systems


Partners: K.U.Leuven/PMA (B), K.U.Leuven/ESAT (B), UCL/CEREM (B), ULB, Ulg/LTAS (B), VUB/ARTI (B), LAAS/CNRS, Toulouse (F), ISVR, Southampton (UK).

Objective: This AMS project aims at providing an integrated design optimisation and control framework to support the development of a new generation of mechatronic systems as required by the ongoing technological and societal paradigm shifts. The most salient feature of a mechatronic system (also called: a machine) is that it generates motion. A machine hence consists of a mechanical structure (distributed flexible multi-body system) of varying complexity. This structure is set in motion by appropriate actuators through motion transmission mechanisms. The resulting motions are measured by means of sensor systems. These can be proprioceptive (encoders, gyroscopes) or exteroceptive (vision systems). A task is transmitted to the machine through some kind of human/machine interface (task programming system), like e.g. haptic interface, programming-by-demonstration interface, interactive autonomy in wheel chairs, etc. The deviation from the programmed motion, detected by the sensors is eliminated by an appropriate motion controller. Salient features of such controller are robustness, accuracy, bandwidth, etc. Controllers can be purely model-based, behaviour-based or of a mixed nature.

Period: Jan 2002 – Dec 2006

Contact: H. Van Brussel

3.7.5IST Project no. 35144, CIRCE : Chiroptera Inspired Robotic CEphaloid: a novel tool for experiments in synthetic biology


Partners: Universiteit Antwerpen (B), Friedrich-Alexander-Universität Erlangen-Nürnberg (D), K.U.Leuven-PMA (B), Loughborough University (UK), University of Edinburgh (UK), Universität Tübingen (D).

Objective: The goal of CIRCE project is to reproduce, at a functional level, the echolocation system of bats by constructing a bionic bat head that can then be used to systematically investigate how the world is not just perceived but actively explored by bats. This bionic bat head will be of similar size to a real bat head to reproduce the relevant physics and consist of an emission/reception system capable of generating/processing bat vocalisations in real-time, a multi-degree of freedom mechanical system to allow realistic pinnae movement and shape control. Constructing the bionic head itself is one objective but a second objective is to gain more insight into neural sensory-data encoding from using the head in echolocation tasks routinely executed by bats.

Period: May 2002 – Apr 2005

Contact: D. Reynaerts, H. Bruyninckx, N. Salustiano, F. Schillebeeckx

3.7.6IST-project no. 2000-31064, OROCOS


Partners: LAAS (F), KTH (Se)

Objective: This project aims at lowering the cost for European SMEs to apply advanced robot control software in their mechatronic products, improving their competitiveness by (i) giving them access to high-quality and flexible robot control software, and (ii) providing a pre-competitive operational standard in relevant data formats and functional implementations.

The technological objectives are:



  • to produce a functional basis for general robot control software,

  • which is released under an open source software license, i.c.,   the (L)GPL (GNU (Lesser) General Public License).

  • which is computer platform independent (i.e., runs on most hardware, or   is portable to any appropriate hardware with modest effort).

  • which is robot independent (i.e., has software modules that can be   adapted (with modest effort) for all known robot hardware, manipulators   as well as mobile robots).

  • which is modular and distributable (e.g., using the CORBA standard for   distributed components).

  • which obeys international standards.

  • which integrates with, and reuses the open source software code of,   relevant complementary projects (e.g., for 3D visualisation, numerical   methods, networking, etc.).

Note that the goal of the OROCOS project is just to produce a functional basis, and not a full-blown robot software system.

Period: Sep 2001 – Aug 2003

Contact: H. Bruyninckx, P. Soetens, T. Issaris

URL: http://www.orocos.org

3.7.7IST-project no. 2001-34166, Geoplex, “Geometric Network Modeling and Control of Complex Physical Systems”


Partners: Universiteit Twente, (NL); Controllab Products B.V., (NL); Université Claude Bernard Lyon, (F); Universitat Politecnica de Catalunya, (E); Ecole Supérieure d’Électricité - SUPELEC, (F); Johannes Kepler Universitaet Linz, (A); K.U. Leuven, PMA, (B); Universitá di Bologna, (I); Centre National de la Recherche Scientifique (CNRS), (F).

Objective: To develop new techniques for modelling, simulation and control of complex physical systems using recent concepts in the geometric formulation of network dynamics as port-Hamiltonian systems.

Period: Feb 2002 – Feb 2006

Contact: H. Bruyninckx, G. Blankenstein

URL: http://www.geoplex.cc

3.7.8IST-project no. 2001-37394, Ocean, “Open Controller Enabled by an Advanced real-time Network”


Partners: FIDIA S.p.A., (I); Universitaet Stuttgart, (D); Rheinisch Westfaelische Technische Hochschule Aachen, (D); Katholieke Universteit Leuven, PMA, (B); HOMAG Holzbearbeitungssysteme AG, (D); Fundacion Fatronik, (E); Fagor Automation, S.  Coop, Spain (B); OSAI S.p.A., (I); Goratu Maquinas Herramienta, S.A., (E); Consiglio Nazionale delle Ricerche, (I).

Objective: The two main objectives of the project are (i) the development of a distributed control system real-time framework (DCRF) for numerical controls based on standardised communication systems and delivered as open source and (ii) an extended component-based open control reference architecture, not delivered as open source but with publicly available new standardised interfaces for motion control components of machine tools, which will make use of the DCRF.

PMA is responsible for the hard real-time aspect of the motion control problem, and the management of the open source software development.



Period: Sep 2002 – Aug 2005

Contact: H. Bruyninckx, H. Van Brussel, B. Koninckx, P. Soetens, P. Issaris

3.7.9ITEA project no. 10260: AMBIENCE: Context Aware Environments for Ambient Services


Partners: Philips Research Eindhoven, Adersa, France Barco, Belgium CCC group, Finland ENST, France pictoid, The Netherlands France Telecom, France Italdesign-Guigiaro, Italy Kaskitech, Finland Knowledge, Greece KU Leuven, Belgium Memodata, France Philips Research, UK Telisma, France Thales Communications, France homson Multimedia, France University of Amsterdam, The Netherlands Universtity of Paris 6, France Universtity of Vienna, Austria TT Electronics, Finland.

Objective: Ambient Intelligence refers to an exciting new paradigm in information technology, in which people are empowered through a digital environment that is aware of their presence and context, and is sensitive, adaptive, and responsive to their needs, habits, gestures and emotions.

It can be defined as the merger of two important visions and trends: "ubiquitous computing" and "social user interfaces". It builds on advanced networking technologies, which allow robust, ad-hoc networks to be formed by a broad range of mobile devices and other objects (ubiquitous- or pervasive computing). By adding adaptive user-system interaction methods, based on new insights in the way people like to interact with computing devices (social user interfaces), digital environments can be created which improve the quality of life of people by acting on their behalf. These context aware systems combine ubiquitous information, communication, and entertainment with enhanced personalization, natural interaction and intelligence. The consortium will generate concepts of Context Aware Environments (CAE), and will develop architectures, methods and tools that allow their development.



Ambient Intelligent environments can be characterized by the following basic elements: ubiquity, awareness, intelligence, and natural interaction.

Period: Jul 2001 – Dec 2003

Contact: H. Van Brussel, M. Nuttin

URL: http://www.extra.research.philips.com/euprojects/ambience/

3.7.10IWT project no. 010463, ARCOMET: Mobile self-erecting tower crane with maximal comfort for the operator: design and construction of a prototype


Partners: Arcomet NV (B), WTCM (B)

Objective: The objective of this project is to develop and to test a prototype of a self-erecting mobile tower crane. The crane will be equipped with an anti-sway advanced control system. PMA/KULeuven will develop in co-operation with Arcomet an anti-sway control system to minimise or completely prevent the oscillating movement of the load during operation (jib trolleying slewing and hoisting). A method for measuring the actual position of the load needs to be developed. The development of the control systems includes a theoretical study, simulation of the dynamic behaviour of the crane structure with load, controller development optimisation, and implementation on a prototype of the mobile tower. The main purpose of this controller development is to make cranes more efficient and safer.

Period: Oct 2002 – Sep 2003

Contact: J. Swevers, H. Van Brussel, K. Smolders

3.7.11IWT project Open Machine Control


Partners: K.U.Leuven-PMA, Bekaert, LVD, Picanol

Objective: This project builds open source software components for a generic infrastructure for machine tool control: realtime feedback kernel, remote access, advanced motion control. The basis is realtime Linux (RTAI). This project is the predecessor of the corresponding research domain in the Flanders' Mechatronics Technology Centre (FMTC).

Period: Nov 2001 - Oct 2003

Contact: H. Bruyninckx, H. Van Brussel, P. Soetens, P. Issaris

3.7.12IWT project no. 020343 Protronic, Determination of the optimal control parameters for systems drive for systems driven by SR-motors


Partners: Protronic N.V. (B), PIH Kortrijk (B), ESAT, PMA

Objective: The switched-relectance motor (SR-motor), a development from the 19th century has recently been rediscovered and found suitable for driving highly dynamic machines, such as modern weaving looms.
The project aims are : accurate modelling of SR-motor based drives developing an identification platform and developing optimal motion control strategies.

Period: Oct 2002 – Sep 2005

Contact: H. Van Brussel

3.7.13K.U.Leuven Concerted Research Action GOA/99/04 and GOA/99/04quatro: Active sensing for intelligent machines


Partners: K.U.Leuven-PMA

Objective: The project deals with the planning of actions for a sensor-based machine which yield new information about the environment. The project aims at developing methods for active sensing, with particular applications in force controlled robots on the one hand and object localisation with simple sensors on the other hand. The project aims especially at working solutions in these application areas. The project works with a parallel strategy: on the one hand, in the top-down approach, the active sensing problem is formulated in a general way; on the other hand, in the bottom-up approach, domain specific sensor based skills are developed. The information gathered by active sensing will be used for high-level control, either by an autonomous robot, or interactively with a human operator, as in teleoperation. Possible application areas are space robotics, nuclear, subsea and medical applications, and service robots.

Period: Jan 1999 – Dec 2003

Contact: J. De Schutter, J. Swevers, H. Bruyninckx

3.7.14Project Volkswagenstiftung :Nonlinear Dynamics Modelling, Detection, Identification and Fault Diagnosis in Industrial Robotics and Machine elements.


Partners: K.U.Leuven-PMA (B), Univ. of Göttingen (D), University of Patras (GR), Univ. of Sheffield (UK)

Objective: This project aims at developing models and identification and fault detection procedures for the nonlinear dynamic behaviour of industrial robotic structures and machine elements. In general, robot joints and machine elements show particularly nonlinear behaviour due to friction, nonlinear flexibility, material nonlinearity, backlash, belt tension, etc. It is widely accepted that it is difficult to and even impossible to build accurate dynamic models accounting for these phenomena based upon first principles alone. For this reason new modeling tools capable of operating on the measured time response of the considered structures and based upon nonlinear dynamics and time series analysis are needed.

Period: Jun 2001 – Mai 2004

Contact: F. Al-Bender, H. Van Brussel

3.7.15IWT - 030391 ACSAS : Advanced Controllers for Semi-Active Suspensions


Partners: Tenneco Automotive St. Truiden Belgium, and Division PMA Department of Mechanical Engineering KULeuven

Objective: Development, validation and tuning of advanced controllers for semi-active suspensions taking into account the main flexibility of the car body and external reference input signals. This includes:

  1. Development of an experimental identification methodology to derive full multiple input multiple output (MIMO) linear dynamic car models for control design.

  2. Development of advanced MIMO controllers for the semi-active suspension, aiming at improving comfort, handling and safety in any circumstance.

  3. These controllers take into account nonlinear damper dynamics and linearized car body dynamics, and appropriately account for additional external reference input signals such as steering angle, throttle position and brake force.

  4. The semi-active suspension system and controllers will be implemented on a test vehicle.

  5. The developed controllers will be tuned and validated on a test vehicle in lab experiments and during ride sessions on test tracks.

Period: Sep 2003 - Dec 2004

Contact: J. Swevers, P. Sas

3.7.16SBO-programme, project 030288, Microsystems for power generation (powerMEMS)


Partners: KULeuven-PMA, KULeuven-TME, KULeuven-MICAS, KULeuven-ELECTA, Interuniversity MicroElectronics Center (IMEC), von Karman Institute for Fluid Dynamics, Royal Military Academy

Objective: The current trends towards miniaturisation, portability and more in general ubiquitous intelligence such as body networks, mobile and wireless computing, vision-based telecom has largely emphasised the need for performant wireless telecommunication protocols in combination with decentralised processing units. The power requirements of such systems or even the concept of ubiquitous power generation have received much less attention and in most cases come down to a traditional concept of battery-operated electronics. Two major observations can be made related to this approach:

  • The increasing demands for portable electronics in conjunction with the interest in zero-emission vehicles generated important improvements in battery performance over the last decade just think of the leaps from NiCd to NiMH and Li-Ion in notebook batteries. Nevertheless, the energy density of even the most performing batteries is about 100 times less than that of fuel based systems. This also explains the enormous interest in fuel cells as they directly convert fuel-based chemical energy in electricity.

  • The limited power available forced engineers to develop power saving electronics, nowadays even extended to a complete power saving concept like the Intel Centrino mobile technology. Due to this evolution electronics became so power efficient that for some applications they can operate on so-called "scavenged" energy, for instance thermal or kinetic energy available in the environment and converted by a dedicated microsystem.

The powerMEMS project emanating from these observations is developing a miniaturised energy generation technology based on both the scavenging and fuel-based principles. This project has two main objectives each corresponding to a class of power generation systems:

  • A first objective is the development of a power scavenging system converting environmental energy into electricity. The system should generate from 100 µW up to 1 mW in optimal conditions. The dimensions should be in the order of 2-4 mm laterally and 0.5-1 mm high.

  • The second objective is the development of a fuel-based power generation system. The system typically has a diameter of 20 mm is 50 mm long and consists of a compressor, combustion chamber, turbine and compressor. It has a power output of typically 10-100 W. For realising these objectives, several secondary objectives have to be reached. They can be derived from the above "ideal" machinery.

Period: Nov 2003 - Oct 2007

Contact: D. Reynaerts

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