ADAPTIVE CONTROL
SYSTEM
BMS COLLEGE OF ENGINEERING
Anil Aithal, Anilkumar, Arvind E B, Arvind Koti H R, Anup R Kamath
Abstract
Adaptive Control(AC) of a machine tools is a recent development
in production engineering which aims at performing the cutting
operation more efficiently. The objective of these adaptive control
systems is to improve the production rate or the part quality by
real-time setting of the optimal machining variables.
Introduction
Usually feeds and speeds are adaptively controlled in
accordance with the data obtained by sensing process
parameters such as tool tip temperature, cutting force,
spindle torque, vibration, etc. AC enables sensing and
automatically correcting for variations in metal cutting
conditions. Two kinds of AC control system are Adaptive
control constraint and Adaptive control optimization . A
simple block diagram of an adaptive control scheme for
machining tools is shown below in fig 1.1
AC feedback System for Milling Machine
Through metal cutting research Cincinnati Milling machine
company has discovered a feedback parameter composed of
cutter torque and deflection sensor measurements whose
relative response to the variables like width of cut , depth of
cut, tool wear etc. is of the same order and magnitude as
their respective influence on cutting speed for constant tool
life. With the help of this feedback parameter, they have
constructed an adaptive controller for a 3-axis numerically
controlled milling machine .The controller is integral with
NC system .The AC- NC control loop is shown below in fig
1.2
Cutter deflection sensed at the spindle nose and cutter torque
sensed in the spindle are continuously sensed by electrical
sensors. Sensor signals are received by the adaptive
controller which computes the feedback quantity and
determines the optimum speed and table rate. There are also
constraints such as maximum deflection and power capacity
of the motor which are also taken care in the controller. It
has been reported that adaptive control produces parts of
desired quality at production rates which are unachievable
using constant speed and feed for cutter an cutting
conditions.
Advantages
Shortening of total cutting times or increase of tool life
and production o0f the machine tool and workpiece
during cut.
Shortening of idle time lost in cutting air.
Programme preparations done more quickly and with less
effort in case of AC applied to NC machine tools.
AC increases tool life and metal removal rate in
machining toughest alloys.
AC can be used on a whole range of machine tools
including drilling, milling, turning and grinding
equipment.
Limitations
A major reason for this situation is the unavailability of
suitable sensors that have a reliable operation in a
manufacturing environment.
The lack of a tool wear sensor is the major obstacle to the
employment of ACO systems.
Force and torque sensors for ACC systems are difficult to
install.
Cooperation with machine tool builders might facilitate
the usage of sensors for AC systems.
Another problem is the interface of an AC system with
CNC units. As the manufacturers have not standardized
interface.
It must be emphasized that most AC systems do not fit
machining cell operation, In machining cells
synchronization among the units in the cell is a prime
requirement.
Conclusion
One of the major difficulties in implementing the more
general adaptive control optimization scheme is the lack
of a reliable method for on-line tool wear sensing.
AC systems offer a tremendous potential for improving
metal removal rates.
Progress in areas such as development of reliable sensors,
machine tool design based on requirements of AC
systems, and development of stable adaptive control
strategies are required.
A major difficulty associated with Automatic Controlled
Constraints type process control in metal-cutting
operations has been controller instability or tool breakage,