Design and Analysis of Robust Nonlinear Synergetic Controller for a PMDC Motor Driven Wire-Feeder System (WFS)

In this paper a robust non-linear synergetic control (NSC) algorithm was developed for the speed control of a permanent magnet DC motor (PMDC) driven wire-feeder systems (WFSs) of gas metal arc welding (GMAW) process. The proposed control approach allows the PMDC motor to track desired trajectories by the output voltage of a full bridge converter with respect to the large torque disturbances, unexpected changes in rotor inertia and makes the wire-feeder unit (WFU) has fast and stable starting process as well as excellent dynamic characteristics. The effectiveness of the proposed control scheme is illustrated by numerical simulations within the MATLAB/SIMULINK environment software. The simulation results clearly demonstrate the significant improvement rendered by the proposed controller in the wire-feeder system’s reference tracking performance, torque disturbance rejection capability, and transient recovery time.