Active regenerative chatter suppression during boring manufacturing process

Machining performance such as that of the boring process is often limited by chatter vibration at the tool–workpiece interface. Among various sources of chatter, regenerative chatter in cutting systems is found to be the most detrimental. It limits cutting depth (as a result, productivity), adversely affects surface finish and causes premature tool failure. Though the machining system is a distributed system, all current active controllers have been designed based upon a simplified lumped single degree of freedom cutting process model. This is because it was found that in the majority of cutting processes, there exists only one dominating mode. However, such simplification does have some potential problems. First, since the system itself is a distributed system, theoretically it consists of infinite number of vibration modes. When the controller is designed to control the dominating mode(s) only, the energy designed to suppress the particular mode(s) may excite the rest of the structural modes, which unavoidably causes the so-called spillover problem. Second, the success of the control design of such simplified single degree of freedom system relies on the availability of accurate model parameters (such as the effective mass, stiffness and damping), which is unfortunately very hard to acquire. This is because the global properties are varying with the metal removal process and the movable components of machine tool. In this paper, an active controller designed from wave point of view is used to absorb chatter vibration energy in a broad frequency band to improve machining performance of a non-rotating boring bar. In contrast to most of the current active chatter control design, the wave controller is designed based on the real distributed cutting system model. The main advantage of such a control scheme to chatter suppression is its robustness to model uncertainties. The control scheme also eliminates the control spillover problem.     

Optimal control for chatter mitigation in milling—Part 2: Experimental validation

The productivity of milling operations in chatter-free conditions can be improved using active structural methods. This paper presents the use of a mechatronic system integrated into the spindle unit combined with two different optimal control strategies. The first one aims to minimize the influence of cutting forces on tool tip deviations. The second one explicitly considers the process interaction and attempts to stabilize the overall closed-loop system for specific machining conditions. The first part of this two-part paper describes the modeling and formulation used for both strategies. In this second part, the experimental validation of the proposed concept is presented.     

Optimal control for chatter mitigation in milling—Part 1: Modeling and control design

Active structural methods constitute a promising way to mitigate chatter vibrations in milling. This paper presents an active system integrated into a spindle unit. Two different optimal control strategies are investigated. The first one only considers the dynamics of the machine structure in the controller design and minimizes the influence of cutting forces on tool tip deviations. The second one takes explicitly the process interaction into account and attempts to guarantee the stability of the overall closed-loop system for specific machining conditions. The modeling and formulation used for both strategies are presented in this first part. A simulation allows the comparison of their respective working principle. The validation of the proposed concept in experimental conditions is described in the second part.     

机械阻尼器对刀具颤振抑制的理论分析及数值模拟

为了抑制高速铣削中的颤振影响,文中提出在刀具中心插入一个分层梁结构机械阻尼器．依靠刀具与阻尼器间的相对运动产生的摩擦阻尼-以耗散振动能量。通过理论分析和数值模拟的方法分别计算了接触压力和阻尼耗散功率．并对两种结果比较分析．找出了造成结果差异的主要原因。     

An intelligent sensor for detection of milling chatter

In this paper, a new real-time sensor system has been developed to detect chatter in milling operations. In the developed sensor system, a pattern recognition technique based on an unsupervised neural network using the adaptive resonance theory (ART) is adopted for detection of milling chatter. The features on the cutting force spectrum are fed into the sensor system to classify the milling process with or without chatter. The experimental results indicate that the proposed sensor system can accurately detect milling chatter regardless of the variation in cutting conditions.     

Fixed‐structure robust controller design for chatter mitigation in high‐speed milling

Chatter is an instability phenomenon in high‐speed milling that limits machining productivity by the induction of tool vibrations, inferior machining accuracy, noise, and wear of machine components. In this paper, a fixed‐structure active chatter control design methodology is proposed, which enables dedicated shaping of the chatter stability boundary such that working points of higher machining productivity become feasible while avoiding chatter. The control design problem is cast into a nonsmooth optimization problem, which is solved using bundle methods. Using this approach, fixed‐structure dynamic (delayed) output feedback controllers can be synthesized. Distinct benefits of this approach are the a priori fixing of the controller order, the limitation of the control action, and the fact that no finite‐dimensional model approximations and online chatter estimation techniques are required. All these benefits are important in milling practice. Representative examples illustrate the power of the proposed methodology in terms of increasing the chatter‐free depth of cut, thereby enabling significant increases in machining productivity. Copyright © 2014 John Wiley & Sons, Ltd.     

基于嵌入式系统的切削颤振在线监测技术研究

针对机床切削过程中的颤振现象难于实时、精确监测和控制的问题,设计了一种基于"FPGA+ARM"结构的切削颤振在线监测系统。切削振动数据采集主控制逻辑用FPGA来实现,ARM则用来实现采集数据的处理及快速发出颤振警报。     

A variable time delay compensator for multivariable linear processes

A variable time delay compensator based on the Smith predictor is proposed. Finite difference and cinematic techniques are employed for a numerical approximation of the variable delay. The resulting multivariable controller is analyzed for robustness using the structured singular value. The technique is demonstrated through two simulated systems: a single-input, single-output numerical example, and a cross-direction paper machine control problem.     

Adaptive chatter mitigation control for machining processes with input saturations

Chatter is an unstable nonlinear dynamical phenomenon often encountered in machining operations because of the self‐excitation mechanism, which may lead to overcut or rapid tool wear, and hence, greatly influence the surface quality and productivity in milling operations. Recent years have witnessed an increasing industrial demand of high quality and high efficiency machining. This paper hereby develops a constrained active adaptive control method to mitigate the chatter dynamics with input saturations. To guarantee the feasibility of the proposed approach, moderate stable conditions of the closed‐loop system are afterwards derived by using the LaSalle–Yoshizawa theorem as well. Finally, numerical simulations are conducted to show the substantially enlarged stable region in the Lobe Diagram. Thus, the method can be expected to improve the efficiency of milling processes. Copyright © 2015 John Wiley & Sons, Ltd.     

A model-based adaptive controller for chatter mitigation and productivity enhancement in CNC milling machines

Seeking a higher level of automation, according to Intelligent Manufacturing paradigm, an optimal process control for milling process has been developed, aiming at optimizing a multi-objective target function defined in order to mitigate vibration level and surface quality, while preserving production times and decreasing tool wear rate. The control architecture relies on a real-time process model able to capture the most significant phenomena ongoing during the machining, such as cutting forces and tool vibration (both forced and self-excited). For a given tool path and workpiece material, an optimal sequence of feedrate and spindle speed is calculated both for the initial setup of the machining process and for the continuous, in-process adaptation of process parameters to changes the current machining behavior. For the first time in the literature, following a Model-Predictive-Control (MPC) approach, the controller is able to adapt its actions taking into account process and axes dynamics on the basis of Optimal Control theory. The developed controller has been implemented in a commercial CNC of a 3-axes milling machine manufactured by Alesamonti; the effectiveness of the approach is demonstrated on a real industrial application and the performance enhancement is evaluated and discussed.     

Suppression of nonlinear regenerative chatter in milling process via robust optimal control

During the milling process, self-excited vibration or chatter adversely affects tool life, surface quality and productivity rate. In this paper, nonlinear cutting forces of milling process are considered as a function of chip thickness with a complete third order polynomial (instead of the common linear dependency). An optimal control strategy is developed for chatter suppression of the system described through nonlinear delay differential equations. Counterbalance forces exerted by actuators in x and y directions are the control inputs. For optimal control problem, an appropriate performance index is defined such that the regenerative chatter is suppressed while control efforts are minimized. Optimal control law is determined based on variation of extremals algorithm. Results show that under unstable machining conditions, regenerative chatter is suppressed effectively after applying the optimal control strategy. In addition, optimal controller guarantees robust performance of the process in the presence of model parametric uncertainties.     

Application study of complex control algorithm for regenerative furnace temperature

Alternative switch combustion mode of air and gas is adopted on the two sides of the regenerative furnace, its temperature is in uncontrolled state in the switching process and the switch period is generally 3～5 min. Thus, the conventional bi-cross limited combustion control method is no longer applicable to the object. This paper makes use of neutral network algorithm to adjust the static operating point. On this basis, fuzzy, control strategy is used for the furnace temperature control. The actual application result shows that the control strategy is effective to solve the problem of the combustion control for regenerative furnace.     

Stability analysis of linear systems subject to regenerative switchings

This paper investigates the stability of switched linear systems whose switching signal is modeled as a stochastic process called a regenerative process. We show that the mean stability of such a switched system is characterized by the spectral radius of a matrix. The matrix is obtained by taking the expectation of the transition matrix of the system on one cycle of the underlying regenerative process. The characterization generalizes Floquet’s theorem for the stability analysis of linear time-periodic systems. We illustrate the result with the stability analysis of a linear system with a failure-prone controller under periodic maintenance.     

Detection of chatter vibration in a drilling process using multivariate control charts

Time series analysis and multivariate control charts are used to devise a real-time monitoring strategy in a drilling process. The process is used to produce holes with high length-to-diameter ratio, good surface finish and straightness. It is subject to dynamic disturbances that are classified as either chatter vibration or spiralling. A new nonparametric control chart for multivariate processes is proposed. It is used to detect chatter vibration which is dominated by single frequencies. The results showed that the proposed monitoring strategy can detect chatter vibration and that some alarm signals are related to changing physical conditions of the process.     

Iterative analysis of Markov regenerative models

Conventional algorithms for the steady-state analysis of Markov regenerative models suffer from high computational costs which are caused by densely populated matrices. In this paper, a new algorithm is suggested which avoids computing these matrices explicitly. Instead, a two-stage iteration scheme is used. An extended version of uniformization is applied as a subalgorithm to compute the required transient quantities “on-the fly”. The algorithm is formulated in terms of stochastic Petri nets. A detailed example illustrates the proposed concepts.     

Control of an active bus voltage limiter with modified space vector pulse width modulation strategies in regenerative applications

This paper proposes an active bus voltage limiter with a modified modulation strategy for bi-directional power flow applications. When the motor is braking, the regenerative energy raises the DC bus voltage. Additional shunt resistors are usually used to dissipate the regenerative energy, which is a waste. The active rectifiers, which are also mentioned as PWM (Pulse Width Modulation) rectifiers, can transfer the regenerative power to the power grid but the cost is high and not economic, especially when the regenerative power is comparatively low. This paper investigates the zero-sequence current produced by the active bus voltage limiter and then presents a modified space vector modulation strategy to effectively suppress the zero-sequence current and keep the unity power factor. The analysis about the control strategy of the topology is carried out. And the algorithms for regenerative applications are discussed. An industrial prototype is built to verify the configuration.     

不确定LTI-SISO系统的低通滤波时滞观测器控制

合理利用时滞可能获得意想不到的性能.研究表明,系统的不确定性以及受到的外部干扰可以利用时滞观测器来进行观测,从而实现系统的鲁棒控制.本文提出了一种低通滤波时滞观测器.避免了常规时滞观测器控制中出现的控制信号颤振,得到了一种结构新颖的控制器.仿真结果表明时滞观测器控制系统可以很好地抑制系统的不确定性以及受到的外部干扰,是一种性能优良的鲁棒控制方法.     

自适应修正Smith算法在时滞系统中的应用

传统的Smith预估补偿控制要求较高的对象模型精度，为了提高系统的鲁棒性，提出了一种改进的Smith预估器。该算法根据历史预估结果动态地对预估输出进行修正，从而提高预估精度。将其应用于大时滞温控系统，取得了准确的预估输出和良好的控制品质。算法实现简单、应用灵活、适应性强，可以应用于其他有滞后影响的场合。     

Observer-based stabilisation of a class of nonlinear systems in the presence of measurement delay

In this paper, the stabilising control problem for a class of nonlinear system in the presence of measurement delay is addressed. A full-order observer is designed to eliminate the effect of variable output time delay, which is bounded and known. Then, the estimated states are utilised for the state feedback control law to stabilise the considered control system. Lyapunov–Razumikhin approach is employed to analyse the stability of the closed-loop system. Unlike the previous work, the exponential convergence of the estimation error is ensured, rather than asymptotic convergence, by designing a delay-dependent gain of the observer. Moreover, comparison with similar work is also made in simulation to illustrate the effectiveness of the proposed strategy.     

Lyapunov matrices: Existence and uniqueness issues

A necessary and sufficient condition for the existence and uniqueness of Lyapunov matrices for neutral type single delay systems is presented.