Implementation of high bandwidth control for rotary and linear motor drives of milling machines PDF
Preview Implementation of high bandwidth control for rotary and linear motor drives of milling machines
IMPLEMENTLAITNIEOANROMFOTHIOGRHDBRAINVEDSWIODFTMHILCLOINNTGRMOALCFHOIRNERSOTARYAND YAZIOELIASTOHME OAFDTIHSESOUEFNRITTAVHTEEIRORSNEIDTQPOYURCIEOTRSFOEEFRMNLETOONEFRTDIPSDTHAOFIOLTIRONHSTEPOHAGPRERHTDYAIEADLCURAFEUTELEFOSIFCLHLOMEONLT UNIVERSITYOFFLORIDA ACKNOWLEDGMENTS ihepaai[Sexyperaress.sm[ylikgenulioreuxdperelsosDrm.yJiarippTrIeucsitaylifoonrhtioxDgru.iJdoahncneZ,ie^gueprpl,o^Dra.nJdophonijSccnhcucelolveer.r Dr.PaulMason,Dr.JacobHammerandDrGregSawyerforservingonmysupervisory oommiiiee.IalsoihonkallofthemembersofIheMachineToolResearchComerforihcir assistanceandfriendship.Iextendspeciallhank.sloAndrewSmithforhishelpInediting thismanuscripL TABLEOFCONTENTS ACKNOWLEDGMENTS ABSTRACT CHAPTERS 1IHiNgThRSOpDeeUdCMTuIeOhNining. TesiBedi 1LITERATUREREVIEW ContFPreIoelDdTCfhooenrotwrrayor.ldl.eTrechni(jiie% PHo-lIenfPilmalcyeCmoennttrCoolntrol ....... OtherControlTheories 3DESIGNFORLINEARMOTION.... TUNINGROTARYMOTORDRIVESFORWIDEBANDWIDTH.. 65ADHSATilnpIUgiapiGdNllLLtiyHIyaenesligaNiaBndFsGdMgsiAwoohcaLNfredrrISeDeLeliwwNeWinTaEdiDMhIdiAroesnDiRodgcvTrareMMylHeoMwOIdoUdFTedeSeeOmeIildRNfiGDcDraRSiivLiIeoIVsnDEISN-FGOMR—OWDIEDECOBNATNRDOWLIDTH 33345563595773 7EFaEieErrDiaFlODRisWiuArRtrDanFceIsLiTnELRiSi'v'.iii.. 7816 FFFSeeeueeemdddmfffaooorrrrwwwyaaarrrdddoFoinnllLLeiernaAednasarclMryesoiwtsoDrriDvreisves 8CONCLUSIONS 97 APPENDICES AMACHINEPARAMETERS BDIGITALFILTERINGTECHNIQUES. REFERENCES BIOGRAPHICALSKETCH IMPLEMENTLAITNIEOANR baiidwidthto100>U;(hu&theballscrowwasobietoreachamaximumaccoleraiionof 2g.Thecomplexityindesigningdigitalrillers.theirlongcalculationtimeandtheirlack ofrobustnessmakethemundesirableinamachinetoolcontroller.Therefore,asliding modecontrollerwasimplementedasasubstituteforthePDcontrollerwithdigitalfilters toacquireahighbandwidth.ITusrobustcontrollerpermittedabandwidthof65Hzto achieveAanlioncecacrlmcomttoirondroifveIgu.nderPDcontrolwasfoundtohavea70Hzbandwidth.No additionalfilleniwererequitedtoachievethisbandwidth.Amajordrawbackofthis driveisitssensitivitytochangesofmassandtoexteraaldisturbanceslikecuttingfoires andfriction. Feedforwardfilterswereappliedonbothdrivestodecreasetrackingerroniduring highaccelenitionmoves.Thesefeedforwardfillersnrducedthetrackingerrortofour countsontheballscrewdriveandtotwocountsonthelinearmotordrive. INCTHRAOPDTUECRTI1ON High'.speedmachiningevolvedindiepaaldecadeaaanimprovementlo convcnilonaJmachining.Advancementsinmicroprocessorsanddigitalsignalprocessors (DSPs)madeitpossibleforthecomputernumericalcontrol(CNC)toaccuratelycontrol feeddrivesathighspeeds.Theprocessorevolutioncoupledwithahighdemandon deliveringmachinedpansatlowercostandmTasterlimespromptedthemachinetool industry10producemachiningcentersdedicatedonlylohigh-speedmachining. Furthermore,high-speedmachiningmadeitpossibletoreplaceothertraditional manufxluringprocesses.Forcaampichigh-speedmachiningofaluminummadeit possibletoproducemonolithicpanstoreplacepartsrobricaiedfromseveralcomponents. AmachinedpartconbemoreaccurateandstructurallysiirfcTthanarivetedpan.From Zelinski[i].thespeedbralteofanF-15nghterjel,madebyBoeingAerospace,cannow bweidmeacphainnweadsfmraomdeonferopmiescheeeotfmseoilaildtaalupmriocneusms.thTartaldaikteisontahlrleyetmhoen1t1hsfotoolalsosnge.mb3lefoaoltlthe 500componentsfororebrake.Thewholepancannowbemachinedin3Uhoursona high-speedmachine.Thelimeandcostofthepanisuemendousiyreduced,butmore imponandy,thequalityofthepanIsimproved. Anotherexompieisthehigh-speedmachiningofhiirdsteeldies.High-speed machiningofdiesdiminalessomeofthestepsfromtheimdiiionalmanufacturingprocess fordies.High-speedmachiningmakesitpossibleforthedieslobemachinedbytaking smallerlocistepsIhusimprovingsurfacefinishanddirainaiinggrindingandhand polishing. Severalaspectsmakeamachiningceniersuilahleforhighspeedmachining: maximumspindlespeed,maximumfeeddrivespeed,lookaheadandhighdole iransmiasionrales.LookaheadisaCNCfeaiurcthatanalyzesihecommandsbeforehand 10determineifthemachineiscapableofhandlingthecommandedmoves.Smith[2] providedamoredeiailcdde.scriplionofhigh-speedmachinedesign. AlthoughallofIheaboveaspecisarenecessaryforahigh-speedmachine,this workconcenlraiesonihefeeddrive.Spocincnlly,ihedifieremlypesoffeeddrivesthat aresuitableforthesemachinesandthecontrolmethodsihniareimplementedtomake themperformcoordinatedmovesathighspeeds. Feeddrivesonhigh-speedmachiningcenterscanexceedspeedsuf0.5m/s.hut thatalonedoesnotmakethemtrulyhighspeed.Highaccelerationisrequiredinorderto attainthemaximumvelocitywithinthecommandedmove.Ahigh-speedfeeddrivemust havehighucccicraiionandhighvelocity. HighSpeedMacltining MostmachinedoircrahcomponentslikethoseinFigure1-1havesmallpocketsto reducelheirmasswithoutdiminishingtheirstrength.ThesepocketsrequirethatIhefeed drivesofihemachinesreach(herequiredspeedasfastaspossibleinordertoproducecost effectivepans.Feeddrivesoneonvemionalmachinescanlypicallyaccelerateupto0.3g whichisusuallynotsufllcienTForhigh-speedmachiningofpockets.Higheracceleration isrequiiedtolakefulladvantageofthefeeddrivesovershortdistances.Anexampleof Iheneedforhi^craccelerationisdieapproximationoFahelicopterrotorgripin Figurel*t.ExampleofchinaJuminumpans Fhcioignguvhre-ensipIie-oe2nd.amiIalmcyha/icsnaheim.noedTcehoefmrmmoaaminnAdlpeod7c0ka7e5fie-eiTnd6riaahtcnedpoafwna2s5w.am4samc6/h3miinmenmdauibsUyi.n21g1ga4ocmvoemnr.vtehnIelni1Co1na4aslemaAmndihac t4arc5acvemellse.raatIttictnoognoskatnatdnhtededscrpeielveeedr2abt2eif0nogmresthiettosdtaracircvtece.idcrIiantsuCidaetscoeetlheBeratcthioeomnhm.iagMnh-odsseptdeeosdfpemtehadec;hmtiohnveeenwiwtaatssrasvpeelnetdfor cmTwoihatmeshmitaiomtunuadlomtemhdsoeprvtehefeeedwastiaounsrm2eep2septmroofssooikrtaimn5oed3ndtmariinnandv2ue9tvleee1ldsomcatstiottbywhehebimumltaeucasihti2irlnogoeouadkmcc4osen8pl5eearemacdtsoifnooivnren.nc2ta4Tis7hoenemAas.dlrbmiTevahfecoehrrieeenna.tcesihlraeoendwpidniatgsn. lookonly12minuteslobehigh-speedmachined.Intheamountoflimeittooktoproduce onepanontheconventionalmachine,fivepanscouldbeproducedonthehigh-speed machine. Insummary,Ilisimportanttoincreasetheaveragevelocityinordertoreducepart productionlime.Thegoalistoachievethehipestacceleraiionpossible. AccelerationandBandwidth dynamicAsc.ceMleortaotrisonhaivselilmiimtietdedbypetawkoafcaccetloerrsa:ttihornusstdecfaipnaecdilbyyoifhtehmeadrxiivemuamndcumrarcehniintehat canbeappliedacrossthewindingsatagiventime.Ingeneral,thisisnonhelimiting fparcetvoer.niAtchceelmearcahtiinoenifsruosmuarlelaychliinmgitheidgbhyacmcaeclherianteiodnysn.amTihces.reaVsiobnraitsitohnastivnitbhreatdiroinvselirail theoverallposicionaibandwidthofthesystem.Thebandwidthofthesystemisan indicationofhowthesystemrespondsloimnsienisinIhelimedomain.
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