Energy Saving for Gantry-Type Feed Drives by Synchronous and Contouring Control

2012 ◽  
Vol 6 (3) ◽  
pp. 363-368 ◽  
Author(s):  
Naoki Uchiyama ◽  
◽  
Yuki Ogawa ◽  
Shigenori Sano
Keyword(s):  
Energy Saving ◽  
Machine Tools ◽  
High Speed ◽  
Controller Design ◽  
Mechanical Damage ◽  
Electrical Energy ◽  
Industrial Applications ◽  
Feed Drives ◽  
Contouring Control ◽  
Synchronous Error

Because feed drives are widely used day and night in industrial applications such as machine tools and coordinated measuring machines all over the world, not only high-speed and high-precision control but also consumed energy saving is required. This paper presents a controller design to reduce consumed energy for gantry-type feed drives that consist of two linear actuators placed in parallel and one linear actuator placed perpendicular to the two parallel actuators. The proposed design is based on synchronous and contouring controllers. The synchronous controller has been studied for reducing synchronous error between two parallel actuators that causes significant mechanical damage, and the contouring controller has been developed for improving contouring performance, especially in machining applications. Experimental results demonstrate the effectiveness of the proposed controller, which reduces consumed electrical energy by about 10%.

Energy Saving in Five-Axis Machine Tools Using Synchronous and Contouring Control and Verification by Machining Experiment

2015 ◽  
Vol 62 (9) ◽  
pp. 5608-5618 ◽  
Author(s):  
Naoki Uchiyama ◽  
Yuki Ogawa ◽  
Abd El Khalick M. ◽  
Shigenori Sano
Keyword(s):  
Energy Saving ◽  
Machine Tools ◽  
Contouring Control ◽  
Five Axis

Sliding Mode Controller Design for High Speed Feed Drives

CIRP Annals ◽  
2000 ◽  
Vol 49 (1) ◽  
pp. 265-270 ◽  
Author(s):  
Y. Altintas ◽  
K. Erkorkmaz ◽  
W.-H. Zhu
Keyword(s):  
High Speed ◽  
Controller Design ◽  
Sliding Mode ◽  
Sliding Mode Controller ◽  
Feed Drives

Asymmetric Arm Design on Delta Robot System

2014 ◽  
Author(s):  
Tsung-Liang Wu ◽  
Jih-Hsiang Yeh ◽  
Cheng-Chen Yang
Keyword(s):  
Energy Saving ◽  
High Speed ◽  
Kinematic Model ◽  
Industrial Applications ◽  
Critical Parameters ◽  
Robot System ◽  
System Cost ◽  
Excited Vibration ◽  
Pick And Place ◽  
Delta Robot

The Delta robot system is widely used in high speed (4 cycles/s at 25-200-25 mm) pick-and-place process in production line. Some industrial applications include photo-voltaic (PV), food process, and electronic assembly, and so on. The energy saving and system cost are two critical parameters for designing the next generation of pick-and-place system. To achieve these goals, a light-weight moving structure with sufficient strength to overcome the excited vibration will be one of the solutions. In this paper, an asymmetric arm design is proposed and fabricated to gain the benefit of strength-to-weight. The asymmetric arm is designed by reinforcing a specific direction and is validated the vibration suppression capability both by simulation and experiment. A position controller that is derived from the kinematic model of Delta robot is utilized to manipulate the robot under a forward-backward motion with a polynomial trajectory with 200 mm displacement. The residual vibration, then, was measured after the forward-backward motion to compare the settling performance between symmetric- and asymmetric-arms on the Delta robot system, respectively. The results conclude as following: (1) The asymmetric arms perform slightly worse (0.03 sec more in settling time) than symmetric arm but there is 15% weight reducing comparing to symmetric arm. (2) Both energy saving and system cost reducing would be achieved by utilizing actuators with lower power consumption and fabrication on carbon fiber arms with mass customization.

High speed contouring control strategy for five-axis machine tools

CIRP Annals ◽  
2010 ◽  
Vol 59 (1) ◽  
pp. 417-420 ◽  
Author(s):  
Y. Altintas ◽  
B. Sencer
Keyword(s):  
Control Strategy ◽  
Machine Tools ◽  
High Speed ◽  
Contouring Control ◽  
Five Axis

Energy Efficiency and Performance Optimized Control of a Hybrid Feed Drive

2015 ◽  
Author(s):  
Molong Duan ◽  
Chinedum E. Okwudire
Keyword(s):  
Energy Efficiency ◽  
Machine Tools ◽  
High Speed ◽  
Control Strategies ◽  
Electrical Energy ◽  
Motor Drives ◽  
Precise Positioning ◽  
Feed Drive ◽  
And Performance ◽  
Precision Machine Tools

Linear motor drives (LMDs) are well known to provide significant advantages in terms of positioning speed and precision over traditional screw drives (SDs), making them better suited for high-speed, high-precision machine tools. However, their use in such machine tools is limited by their tendency to consume a lot of electrical energy and cause thermal issues that help drive up costs. A hybrid feed drive (HFD) has been proposed as a possible solution to this dilemma. The HFD combines LMD and SD actuation to achieve speeds and accuracies similar to LMDs while consuming much less energy. This paper explores control strategies to further improve the performance of the HFD without unduly sacrificing its efficiency. First, it highlights two performance limitations of the controller proposed for the HFD in prior work, namely, imperfect tracking and suboptimal feedback gains. Then it compares two approaches for achieving perfect tracking with regard to performance and energy efficiency. Finally, it presents an approach for optimizing the feedback gains of the HFD to achieve the best positioning performance. Simulations and experiments are used to demonstrate significant gains in precise positioning using the methods proposed in this paper, while maintaining superb energy efficiency relative to an equivalent LMD.

Reduction of Consumed Energy and Control Input Variance in Machine Tool Feed Drives by Contouring Control

2009 ◽  
Vol 3 (4) ◽  
pp. 401-407 ◽  
Author(s):  
Naoki Uchiyama ◽  
◽  
Takaya Nakamura ◽  
Kazuo Yamazaki ◽  
Keyword(s):  
Controller Design ◽  
Electricity Consumption ◽  
Contour Error ◽  
Control Input ◽  
Control Performance ◽  
Feed Drives ◽  
Controller Gain ◽  
Contouring Control ◽  
And Control ◽  
Better Than

Contouring control has been widely studied to reduce contour error, defined as error components orthogonal to desired contour curves. Its effectiveness has, however, to the best of our knowledge, only been verified through comparative experiments using industrial non-contouring (independent axial) controllers or conventional contouring controllers such as the cross-coupling controller. Because control performance depends largely on controller gain, these comparisons have problems in showing the effectiveness of contouring control, meaning that similar control performance could be attained if non-contouring controller gain were appropriately assigned. This paper presents contouring controller design for biaxial feed drives that reduces controller gain, rather than contour error, better than conventional independent axial controllers. The contouring controller is shown in experiments to effectively reduce control input variance and electricity consumption on average by 4.5%.

Energy saving control in five-axis machine tools using contouring control

2013 ◽  
Author(s):  
Naoki Uchiyama ◽  
Yuki Ogawa ◽  
A. El Khalick M. ◽  
Shigenori Sano ◽  
Kazuo Yamazaki
Keyword(s):  
Energy Saving ◽  
Machine Tools ◽  
Contouring Control ◽  
Energy Saving Control ◽  
Five Axis

Comparison Study of Contouring Control Systems

2006 ◽  
Vol 505-507 ◽  
pp. 1183-1188
Author(s):  
C.C. Peng ◽  
Chieh Li Chen
Keyword(s):  
Control Systems ◽  
High Speed ◽  
Controller Design ◽  
Control Strategies ◽  
Comparison Study ◽  
External Disturbances ◽  
Control Structures ◽  
Contouring Control ◽  
System Uncertainties ◽  
Distinguishing Features

The main difficulties in dealing with extremely high speed precision contouring control are system uncertainties and external disturbances, which exist in all CNC mechanisms and hard to be eliminated. Up to the present, numerous control strategies for multi-axial contouring control have been proposed. Some of them are only for specific contour conditions. This paper surveys several formulations in dealing with contouring control system, instead of the controller design. The distinguishing features of these control structures are also addressed.

Optimal Contouring Control of Multi-Axial Feed Drive Servomechanisms

1989 ◽  
Vol 111 (2) ◽  
pp. 140-148 ◽  
Author(s):  
P. K. Kulkarni ◽  
K. Srinivasan
Keyword(s):  
Controller Design ◽  
Contour Error ◽  
Loop Control ◽  
Feed Drive ◽  
Feed Drives ◽  
Straight Line ◽  
Contouring Control ◽  
Contouring Accuracy ◽  
Closed Position ◽  
The Individual

The capability of multi-axial machine tool feed drives to follow specified trajectories accurately is an important requirement for precision machining and especially so in applications involving high contouring speeds. In current generation machine tools, contouring is achieved by coordinating the commands to the individual feed drives, and implementing closed position loop control for each axis. The present paper deals with the evaluation of a cross-coupled compensator aimed specifically at improving contouring accuracy in multi-axial feed drives. The controller design is formulated as an optimal control problem. The performance index to be minimized weights the contour error explicitly. The controller is evaluated experimentally on a microcomputer controlled two-axis positioning table. Controller performance is evaluated for straight line, cornering and circular contours at feed rates varying from 2.25 m/min to 5.63 m/min. Measures of the steady state and transient contour errors are considered. The experimental results show that the proposed controllers reduce contouring errors considerably as compared to conventional uncoupled control of the multiple axes. The control action of the optimal controller is compared with that of more conventional uncoupled controllers.

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