Energy Saving in Feed Drive Systems Using Sliding-Mode-Based Contouring Control With a Nonlinear Sliding Surface

Reduction of contour error, which is defined as the shortest distance between the actual position of the cutting tool and the reference trajectory, is an essential requirement in machining by multiaxis feed drive systems. In addition, because these machines operate all the time in industrial applications all over the world, reduction of the consumed energy in these machines contributes to environmental, natural resources, and energy problems. This paper presents a novel sliding mode contouring controller with a nonlinear sliding surface to improve the machining accuracy of the biaxial feed drive systems. Because the contour error is more important than the tracking error with respect to each feed drive axis, the contour error component is included in the proposed sliding surface. The advantage of including the contour error in the proposed sliding surface is that the damping ratio of the system changes from its initial low value to final high value as the contour error changes from high value to small value and vice versa. Hence, the proposed algorithm allows a closed-loop system to simultaneously achieve low energy consumption and small settling time, resulting in a smaller error. By using the proposed method, experimental results for a biaxial feed drive system show a significant performance improvement in terms of the contour error. In addition, the proposed approach reduces the control input variance by about 41.2 % and 14.9 % for x - and y-axis, respectively, and consumed energy by about 23.7 % and 5.5 % for the respective axis from the conventional method with a linear sliding surface.

[1]  Sanjib Kumar Panda,et al.  Sliding-mode position controller for linear permanent magnet brushless DC servo motors , 2003, The Fifth International Conference on Power Electronics and Drive Systems, 2003. PEDS 2003..

[2]  Bin Yao,et al.  Coordinated Adaptive Robust Contouring Controller Design for an Industrial Biaxial Precision Gantry , 2010, IEEE/ASME Transactions on Mechatronics.

[3]  Dong Sun,et al.  Design of an enhanced nonlinear PID controller , 2005 .

[4]  J. Swevers,et al.  Extended Bandwidth Zero Phase Error Tracking Control of Nonminimal Phase Systems , 1992 .

[5]  Vimal Dhokia,et al.  Energy efficient process planning for CNC machining , 2012 .

[6]  Chih-Ching Lo,et al.  Tangential-Contouring Controller for Biaxial Motion Control , 1999 .

[7]  Masayoshi Tomizuka,et al.  Zero Phase Error Tracking Algorithm for Digital Control , 1987 .

[8]  David W. Clarke,et al.  Generalized predictive control - Part I. The basic algorithm , 1987, Autom..

[9]  Naoki Uchiyama,et al.  The effectiveness of contouring control and a design for three-dimensional machining , 2009 .

[10]  A. Khajepour,et al.  Application of Adaptive Sliding Mode Control for Regenerative Braking Torque Control , 2012, IEEE/ASME Transactions on Mechatronics.

[11]  Triet Hung Ho,et al.  Speed Control of a Hydraulic Pressure Coupling Drive Using an Adaptive Fuzzy Sliding-Mode Control , 2012, IEEE/ASME Transactions on Mechatronics.

[12]  Ming-Yang Cheng,et al.  On real-time contour error estimation for contour following tasks , 2005, Proceedings, 2005 IEEE/ASME International Conference on Advanced Intelligent Mechatronics..

[13]  C. Mahanta,et al.  Nonlinear sliding surface based second order sliding mode controller for uncertain linear systems , 2011 .

[14]  Zexiang Li,et al.  A Novel Contour Error Estimation for Position Loop-Based Cross-Coupled Control , 2011, IEEE/ASME Transactions on Mechatronics.

[15]  Athulan Vijayaraghavan,et al.  Automated energy monitoring of machine tools , 2010 .

[16]  Meir Pachter,et al.  Toward improvement of tracking performance nonlinear feedback for linear systems , 1998 .

[17]  Yusuf Altintas,et al.  Sliding Mode Controller Design for High Speed Feed Drives , 2000 .

[18]  A. Verl,et al.  ENERGY CONSUMPTION FORECASTING AND OPTIMISATION FOR TOOL MACHINES , 2009 .

[19]  E. Camacho,et al.  Generalized Predictive Control , 2007 .

[20]  Bin Yao,et al.  An Orthogonal Global Task Coordinate Frame for Contouring Control of Biaxial Systems , 2012, IEEE/ASME Transactions on Mechatronics.

[21]  N. Uchiyama,et al.  Reduction of control input variance of feed drive systems using sliding-mode control with non-linear sliding surface , 2013, 2013 IEEE International Conference on Mechatronics (ICM).

[22]  Bin Yao,et al.  Global Task Coordinate Frame-Based Contouring Control of Linear-Motor-Driven Biaxial Systems With Accurate Parameter Estimations , 2011, IEEE Transactions on Industrial Electronics.

[24]  Benjamin Jones,et al.  Energy efficiency improvements in dry drilling with optimised diamond-like carbon coatings , 2008 .

[25]  Pau-Lo Hsu,et al.  Estimation of the contouring error vector for the cross-coupled control design , 2002 .

[26]  Chao-Chung Peng,et al.  Biaxial contouring control with friction dynamics using a contour index approach , 2007 .

[27]  Aun-Neow Poo,et al.  Tracking and contour error control in CNC servo systems , 2005 .

[28]  Bin Yao,et al.  This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Coordinated Adaptive Robust Contouring Control of an Industrial Biaxial Precision Gantry with C , 2022 .

[29]  Manfred Weck,et al.  Sharp Corner Tracking Using the IKF Control Strategy , 1990 .

[30]  Didier Dumur,et al.  Generalized Predictive Cascade Control (GPCC) for Machine Tools Drives , 1990 .

[31]  Timothy G. Gutowski,et al.  An Environmental Analysis of Machining , 2004 .

[32]  Shyh-Leh Chen,et al.  Contouring control of biaxial systems based on polar coordinates , 2002 .

[33]  Shigenori Sano,et al.  Reduction of Electrical Energy Consumed by Feed-Drive Systems Using Sliding-Mode Control With a Nonlinear Sliding Surface , 2014, IEEE Transactions on Industrial Electronics.

[34]  Yoram Koren,et al.  Cross-Coupled Biaxial Computer Control for Manufacturing Systems , 1980 .

[35]  Qingsong Xu,et al.  Development and Assessment of a Novel Decoupled XY Parallel Micropositioning Platform , 2010, IEEE/ASME Transactions on Mechatronics.

[36]  David W. Clarke,et al.  Generalized Predictive Control - Part II Extensions and interpretations , 1987, Autom..

[37]  George T.-C. Chiu,et al.  Adaptive robust contour tracking of machine tool feed drive systems-a task coordinate frame approach , 1997, Proceedings of the 1997 American Control Conference (Cat. No.97CH36041).

[38]  Yusuf Altintas,et al.  Modeling and Control of Contouring Errors for Five-Axis Machine Tools—Part II: Precision Contour Controller Design , 2009 .