Improving the machine accuracy through machine tool metrology and error correction

Improving both the positioning accuracy and contouring accuracy of a vertical machining centre has been studied by using a machine tool metrology and in-house error correction techniques. Contouring errors caused by the servo lag and friction of servomechanisms were measured by the circular test and then reduced by off-line parameter tuning of the CNC and servo-driver. The quasistatic thermal errors were predicted online using a neural network based model which was calibrated in advance via a quick set-up and multiple-error measurement system consisting of a spindle-mounted probe and artifacts. Positioning errors caused by both the static geometric errors and thermal effects were eliminated in real-time by a PC based software error compensation scheme integrated with the CNC controller through digital communication. An error reduction of 70% was achieved after error compensation and CNC tuning.     

A control strategy with motion smoothness and machining precision for multi-axis coordinated motion CNC machine tools

The advanced manufacture technology requires that multi-axis coordinated motion computer numerical control (CNC) machine tools have the capability of high smoothness and high precision. At present, the study of the motion smoothness mainly concentrates on the acceleration and deceleration control method and the look-ahead process of velocity planning in the interpolation stage. The control strategy of the contouring error mainly focuses on tracking error control, cross-coupling control, and optimal control. In order to improve the motion smoothness and contouring precision for multi-axis high-speed CNC machine tools, a multi-axis modified generalized predictive control approach was presented in this paper. In the control strategy, the estimation models of tracking error, contouring error, velocity error, and acceleration error were structured separately. A new improved quadratic performance index was proposed to guarantee the minimum of these errors. Generalize predictive control was also introduced, a multi-axis generalized predictive control model was deduced for motion smoothness and machining precision for multi-axis coordinated motion CNC system, and an approved multi-axis generalized predictive controller based on the model was designed in this paper. The proposed predicted control approach was evaluated by simulation and experiment of circular, noncircular, and space line trajectories, respectively. These simulative and experimental results demonstrated that the proposed control strategy can significantly improve the motion smoothness and contouring precision. Therefore, the new position control method can be used for the servo control system of multi-axis coordinated motion CNC system, which increases motion smoothness and machining precision of CNC machine tools.     

Design methodology for fully dynamic-controlled polynomial profiles and reduced tracking error in CNC machines

High speed and high precision on computer numerically controlled (CNC) machines are major issues for most industrial automation processes. Among the most important factors for precise motion control are the control law, the controller implementation, and the profile reference. The effects of the control law and controller implementation on the tracking error in CNC machines have been widely studied, while the issue of profile reference has not received the required attention. To improve the dynamics provided by the conventional profile reference, several techniques have been proposed, focusing on peak jerk limitation. The novelty of this work is to develop a generalized methodology designed for producing dynamically constrained higher degree piecewise polynomial profiles, without limits in maximum polynomial degrees. They lead to define in an arbitrary way the dynamics shape, while the peak dynamics values constrained are maintained in order to improve the tracking error on CNC systems and giving the possibility to design fully dynamic-controlled trajectories. For experimentation purposes, a two-axis proportional–integral–derivative controller and profile reference generator are implemented in a low-cost field programmable gate array. The experimentation demonstrates the efficiency of the proposed methodology, showing the peak jerk and tracking error reduction, compared against recent reports from literature.     

Disturbance observer and adaptive controller design for a linear-motor-driven table system

This paper presents a disturbance observer and adaptive controller design for a direct drive motion control system. An indirect adaptive controller is implemented to achieve desired tracking performance as well as deal with system parameters variation. To reduce tracking errors, a newly designed adaptive feed-forward controller is proposed based on an on-line estimated inverse model of the linear motor drive system. A digital disturbance observer is implemented to be included in the proposed feedback-feed-forward control structure to compensate for the undesired nonlinearity and external load disturbance of the direct drive system. Experimental results show that this control scheme can achieve superior contouring accuracy, disturbance rejection and robustness under the influence of friction and cogging force.     

Experimental implementation of Taylor series expansion error compensation on a bi-axial CNC machine

In this paper, a new model-based Taylor series expansion error compensation (TSEEC) strategy is proposed to improve the contouring accuracy for computer numerically controlled (CNC) machines. In TSEEC, the contour error compensation problem is formulated as a Taylor series expansion problem, in which the value of the contour error is expanded around the reference points and the compensation components are calculated as the deviations from the reference points. Simulations show that, with perfect knowledge of the axial dynamics, zero contour errors can be achieved with TSEEC for both linear and circular contours. Due to modeling errors, external disturbances, and measurement noise, some modifications and experimentation need to be made to determine suitable parameters for implementation of the TSEEC scheme on a real machine. These measurements include a low-pass filter, a choice of a compensation target, and a compensation gain. Experimental results show the effectiveness of TSEEC in reducing contour errors and demonstrate the superiority of TSEEC over inverse feedforward compensation and cross-coupled control in improving the contouring accuracy.     

Application of Ball Bar System and Genetic Algorithms for CNC Lathe Contouring Compensation

There is considerable interest in the development and improvement of contouring test devices for CNC machines. When ball bar systems are employed to test CNC lathes, the eccentricity cannot be determined accurately from the sampled quadrant contouring data via the least-squares method. Geometric errors, such as squareness and deformation errors, are underestimated, causing significant errors in eccentricity values. Thus, one device with one method is suggested herein for improved lathe compensation for a given radius. Further, it is found that by adjusting a lathe during initial setting-up, for the eccentricity determined via the proposed methodology, the real geometric error of the turned part can be significantly reduced. Thus, it is very important to obtain the correct eccentricity and minimum zone solution. In this paper, genetic algorithms (GAs) are employed to solve the minimum zone solution. Simulated data and analysed results prove that the proposed method is superior to the least-squares method.     

Adaptive robust motion trajectory tracking control of pneumatic cylinders with LuGre model-based friction compensation

Friction compensation is particularly important for motion trajectory tracking control of pneumatic cylinders at low speed movement. However, most of the existing model-based friction compensation schemes use simple classical models, which are not enough to address applications with high-accuracy position requirements. Furthermore, the friction force in the cylinder is time-varying, and there exist rather severe unmodelled dynamics and unknown disturbances in the pneumatic system. To deal with these problems effectively, an adaptive robust controller with LuGre model-based dynamic friction compensation is constructed. The proposed controller employs on-line recursive least squares estimation（RLSE） to reduce the extent of parametric uncertainties, and utilizes the sliding mode control method to attenuate the effects of parameter estimation errors, unmodelled dynamics and disturbances. In addition, in order to realize LuGre model-based friction compensation, the modified dual-observer structure for estimating immeasurable friction internal state is developed. Therefore, a prescribed motion tracking transient performance and final tracking accuracy can be guaranteed. Since the system model uncertainties are unmatched, the recursive backstepping design technology is applied. In order to solve the conflicts between the sliding mode control design and the adaptive control design, the projection mapping is used to condition the RLSE algorithm so that the parameter estimates are kept within a known bounded convex set. Finally, the proposed controller is tested for tracking sinusoidal trajectories and smooth square trajectory under different loads and sudden disturbance. The testing results demonstrate that the achievable performance of the proposed controller is excellent and is much better than most other studies in literature. Especially when a 0.5 Hz sinusoidal trajectory is tracked, the maximum tracking error is 0.96 mm and the average tracking error is 0.45 mm. This paper constructs an adaptive robust controller     

High accuracy motion control of linear motor drive wire-EDM machines

This paper aims to develop and investigate a permanent magnet linear-motor-driven table system for a wire-EDM machine. A dynamic model and system identification of `the linear motor system have been derived and analyzed. The linear motor drive system has nonlinear and time-varying behaviors because of the effect of irregular friction of the sliding surface and cogging force. Therefore, a conventional digital controller may not suffice to provide a high contouring accuracy as well as adequate disturbance rejection and parameter variation robustness. An indirect adaptive controller (IAC), combined with a neural network-based feedforward controller (NNBFC) is proposed to improve the contouring performance of the linear motor system. Experimental results not only indicate that the proposed control scheme can achieve a high contouring accuracy of ± 0.3 μm, they also demonstrate that the developed linear motor drive wire-EDM machine can meet the requirement for micro machining. The maximum contour error of circular trajectory at a feed-rate of 0.1 mm/min was significantly reduced from 8 μm to 0.5 μm in comparison with proportional-integral-derivative (PID) controller.     

The influence of friction on contouring accuracy of a Cartesian guided tripod machine tool

This paper is focused on the friction-induced contouring errors of a three-axis parallel kinematic machine (PKM) called a Cartesian-guided tripod (CGT). A dynamic model of the CGT including the nonlinear dynamic, mechanical compliance and mechanical friction has been formulated. Servo control characteristics of the formulated CGT dynamic model are analyzed based on the conventional P-PI controller and feedforward friction compensation implemented in the joint level control scheme. Quantitative analysis and comparison of the various friction sources from the actuated joints (ballscrew/nut) and passive joints (balljoint and guideway) have been conducted. Analysis results show that the ballscrew/nut friction produces the most significant friction-induced contouring errors. The ball-joint friction and linear-guide friction induced contouring errors are two-order and one-order, respectively, lower than the errors by the ballscrew friction. The main reason is that the equivalent friction torques of these two friction sources coupled into the servo drive loop are reduced by the leverage effect of the driving leg length. It was also found that the conventional feedforward friction compensation can effectively reduce the ballscrew-friction-induced contouring errors. However, if not properly compensated, ballscrew friction could excite significant platform-leg structural vibration because the tripod-based PKM usually has a high compliance vibration mode in the horizontal platform-leg direction. The friction-excited structural vibration can be reduced by putting vibration absorbers on the guideways of the passive leg to damp out the platform-leg vibration. From the primary analysis results, it can be seen that the proposed tripod based PKM has high potential for high-speed 5-axis machining applications.     

Identification of and compensation for backlash on the contouring accuracy of CNC machining centres

The paper describes a technique for the identification of and compensation for backlash on the contouring accuracy of computer numerically controlled (CNC) machining centres. A circular test that has been developed for rapidly checking the contouring accuracy of CNC machine tools is used to measure the contouring error due to backlash. Backlash error on the contouring profile is found as the direction of motion is reversed. A compensation strategy based on a simulated annealing (SA) optimisation algorithm is then developed to reduce the backlash error. Computational simulations and experimental tests have shown that the contouring error due to backlash can be greatly reduced by using this new approach.     

Robust friction compensation for submicrometer positioning and tracking for a ball-screw-driven slide system

Ball-screw-driven slide systems are largely used in industry for motion control applications. Their performance using standard proportional-integral-derivative (PID) control algorithm is unsatisfactory in submicrometer motion control because of nonlinear friction effects. In this article, controllers based on a bristle-type nonlinear contact model are developed and implemented for submicrometer motion. For submicrometer positioning, a proportional-derivative (PD) control scheme with a nonlinear friction estimate algorithm is developed, and its performance is compared with that of a PID controller. For tracking, a disturbance observer was added to reject external disturbances and to improve robustness. The experimental results indicate that the proposed controller has consistent performance in positioning with under 1.5% of steady-state error in the submicrometer range. For tracking performance, the proposed controller shows good and robust tracking with respect to parameter variation.     

840D数控系统摩擦补偿的实现

首先介绍了数控伺服系统中摩擦的非线性特征,以及摩擦非线性导致的轮廓精度变差现象.然后,介绍了西门子840D数控系统摩擦补偿的原理、模式选择、步骤,以及如何利用自适应摩擦补偿在汉江HJ044五坐标五联动数控镗铣床上消除圆插补中的过象限误差.最后,验证了自适应摩擦补偿的效果.     

Feedback attitude sliding mode regulation control of spacecraft using arm motion

The problem of spacecraft attitude regulation based on the reaction of arm motion has attracted extensive attentions from both engineering and academic fields.Most of the solutions of the manipulator’s motion tracking problem just achieve asymptotical stabilization performance,so that these controllers cannot realize precise attitude regulation because of the existence of non-holonomic constraints.Thus,sliding mode control algorithms are adopted to stabilize the tracking error with zero transient process.Due to the switching effects of the variable structure controller,once the tracking error reaches the designed hyper-plane,it will be restricted to this plane permanently even with the existence of external disturbances.Thus,precise attitude regulation can be achieved.Furthermore,taking the non-zero initial tracking errors and chattering phenomenon into consideration,saturation functions are used to replace sign functions to smooth the control torques.The relations between the upper bounds of tracking errors and the controller parameters are derived to reveal physical characteristic of the controller.Mathematical models of free-floating space manipulator are established and simulations are conducted in the end.The results show that the spacecraft’s attitude can be regulated to the position as desired by using the proposed algorithm,the steady state error is 0.000 2 rad.In addition,the joint tracking trajectory is smooth,the joint tracking errors converges to zero quickly with a satisfactory continuous joint control input.The proposed research provides a feasible solution for spacecraft attitude regulation by using arm motion,and improves the precision of the spacecraft attitude regulation.     

高速进给的自适应滑模控制器设计

数控技术的发展要求伺服进给系统具有高带宽、强的扰动抑制能力和鲁棒性,以取得高精度的轨迹跟踪性能.设计了一种具有鲁棒性的自适应滑模控制器,利用一阶共振陷波滤波器抑制系统的共振,同时在控制环中加入摩擦前馈补偿,提高进给运动反向时的精度.最后通过实验和仿真比较了各种控制策略的优劣,验证了提出的带有摩擦力前馈补偿和陷波滤波器的滑模控制策略不仅可以获得高精度的加工轨迹,而且具有良好的抗干扰性和鲁棒性.     

Control system design of a linear motor feed drive system using virtual friction

This paper proposes a friction compensator and a design method for control systems to improve the response characteristics of linear motor feed drive systems. The proposed friction compensator cancels the real nonlinear friction of feed drive systems by using the nonlinear friction model proposed in this study and introduces virtual linear friction to facilitate the control system design. The proposed design method enables the determination of servo gains and friction compensator parameters that lead to desirable tracking performance and disturbance rejection without many trial-and-error tuning processes. In addition, the proposed method facilitates the design of the velocity feedforward compensator by using the inverse transfer function of the velocity control loop to correct the position tracking errors for various position commands. The effectiveness of the proposed method with the friction compensator and the velocity feedforward compensator was verified in simulations and experiments using a one-axis feed drive system consisting of a rod-type linear motor and linear roller guides. The results confirmed that the proposed method enables desirable overshoot-free responses and corrects motion trajectory errors due to nonlinear friction characteristics, and the proposed velocity feedforward compensator can correct tracking errors in both constant velocity motion and circular motion.     

基于自抗扰控制的转台伺服系统摩擦非线性补偿仿真研究

为克服非线性摩擦在转台伺服系统低速运行时对控制性能的影响,设计一种线性自抗扰控制器.该控制器采用线性扩张状态观测器及线性反馈,将摩擦作为系统总扰动进行实时估计,并加以补偿.基于Lugre摩擦模型建立转台伺服系统的数学模型,对这种线性自抗扰控制器进行仿真实验.结果表明,和传统PID控制器相比,所设计的控制器对非线性摩擦有良好的抑制作用,同时具有响应速度快、稳态误差小,抗扰能力强的特点.     

Direct adaptive robust tracking control for 6 DOF industrial robot with enhanced accuracy

A direct adaptive robust tracking control is proposed for trajectory tracking of 6 DOF industrial robot in the presence of parametric uncertainties, external disturbances and uncertain nonlinearities. The controller is designed based on the dynamic characteristics in the working space of the end-effector of the 6 DOF robot. The controller includes robust control term and model compensation term that is developed directly based on the input reference or desired motion trajectory. A projection-type parametric adaptation law is also designed to compensate for parametric estimation errors for the adaptive robust control. The feasibility and effectiveness of the proposed direct adaptive robust control law and the associated projection-type parametric adaptation law have been comparatively evaluated based on two 6 DOF industrial robots. The test results demonstrate that the proposed control can be employed to better maintain the desired trajectory tracking even in the presence of large parametric uncertainties and external disturbances as compared with PD controller and nonlinear controller. The parametric estimates also eventually converge to the real values along with the convergence of tracking errors, which further validate the effectiveness of the proposed parametric adaption law.     

A receding time horizon optimal feedrate control with cross-coupled structure for multiaxial systems

This work is concerned with the development of digital contouring controller for multiaxial servosystem. digital optimal contouring controller is proposed to improve the contouring performance by coordinating each of the controllers of multiple feed drives. The optimal control formulation explicitly includes the contour error in the performance index to be minimized. The contouring control is simulated for straight line and circular contours. Substantial improvement in contouring performance is obtained for a range of contouring conditions. Both steady state and transient error measures have been considered. The simulation results show that the proposed controller reduces contouring errors considerably as compared to the conventional uncoupled control for biaxial systems. The presented study has established the potential of the proposed controller to improve contouring performance. The concepts used here seem to be general enough to be useful in other coordinated motions.     

基于预滑—动态摩擦力矩估计模型的自适应前馈补偿方法

根据数控交流伺服工作台进给系统从静止到宏观运动的过渡时间,和零速度时刻的指令加速度大小呈反比关系,区分摩擦力矩的预滑动区和滑动区,由此提出基于力矩值估计的摩擦补偿方法;在设定指令加速度后,基于命令力矩值的摩擦力矩模型,不需要测量速度就可以补偿工作台进给系统中的摩擦。同时,考虑到参数的不确定性,设计非线性摩擦自适应控制方案,对其稳定性进行理论证明。在交流伺服工作台进给系统上对基于摩擦力矩值估计的自适应前馈补偿方法进行验证。试验结果表明,基于预滑—动态摩擦力矩估计模型的自适应前馈补偿方法能实现在不同指令加速度下对期望轨迹的跟踪,并能大大提高系统的跟踪精度。     

A Linear Cross-Coupled Control System for High-Speed Machining

We present a linear cross-coupled controller to improve highspeed contouring accuracy independently of tracking accuracy in a biaxial machine tool feed drive servomechanism. Unlike conventional cross-coupled controllers, the cross-coupled controller presented here is a linear system, so it is very easy to perform the stability and steady-state error analysis, and to optimise the controller parameters. The proposed controller is evaluated experimentally on a CNC LOM machine and compared to an uncoupled controller and a conventional cross-coupled controller. Controller performance is evaluated for a circular contour at a feedrate of 30 m min _1 . The experimental results show that the proposed controller can greatly reduce the contour error at large feedrates. The linear cross-coupled controller is simple to implement and is practical.