Control of linear motor machine tool feed drives for end milling: Robust MIMO approach

Linear motors are getting promising for use as high speed, high accuracy machine tool feed drives. The cutting force in the machining process are directly reflected to the linear motor due to no gearing mechanism. To achieve high accuracy machining, the controller for the linear motor system should be designed to compensate for the cutting force.

In this work, a MIMO H_∞ controller for the linear motor machine tool feed drives has been designed to reduce tracking errors induced by cutting forces for end milling. The controller is designed using normalized coprime factorization method for the dynamic model of the linear motor system. The model includes constant in-line and cross coupling force gain, since the feedback cutting force can be considered as the product of the constant gain and the moving velocity of each axis.

Analysis of the structured singular value shows that the designed controller has good robust performance despite wide variations of the cutting force and physical parameters. It is directly implemented on a linear motor X–Y table which is mounted on a milling machine to have cutting experiments via a DSP board. Experimental results verified effectiveness of the proposed scheme to suppress the effects of the cutting force in the high feed rate.