L3

ADAPTIVE CONTROL SYSTEMS

Another step towards true automation by adding decision making

Few Terms
y IPC (industrial process control) :- like controlling temp

y y y y y

,pressure etc by sensing device and controlling by actuators in boilers. CADP :- Computer added data processing SPMM :- Special purpose manufacturing m/c NC :- Numerically controlled CNC:- Computerized Numerical controlled DNC :- Direct Numerical controlled

It is a feedback system in which cutting speed and feed automatically adopt themselves to actual conditions of machining process and varies as per cutting progresses

ADAPTIVE CONTROL SYSTEMS

It is the technique of automatically adjusting of cutting parameters such as speeds, feeds and depth of cuts etc. to an optimum satisfaction level during machining operation and the maximum metal removal which will result in minimum machining cost.

ADAPTIVE CONTROL (AC)

In CNC mechanism the cutting speed and feed rates are prescribed by the part programmer. The determination of these operating parameters depends on the Knowledge and experience regarding the work piece, tool materials, coolant conditions and other factors. By contrast in adaptive control machining, there is improvement in the production rate and reduction in the machining cost as a result of calculating and setting of optimal parameters during machining. This calculation is based on measurements of process variables in real time and followed by a subsequent on-line adjustments of the parameters subjected to machining constraints in order to optimize the performance of the overall system.

Block Diagram of Adaptive control system

Tape

NC System Position feedback

Drive command

Adaptive control Constraints Performance index Strategy

Sensors

The three functions of adaptive control are: 1. Identification function:- This involves determining the current
performance of the process or system. Normally, the performance quality of the system is defined by some relevant index of performance. The identification function is concerned with determining the current value of this performance measure by making use of the feedback data from the process.

2. Decision function:Once the system performance is determined, the next function is to decide how the control mechanism should be adjusted to improve process performance. The decision procedure is carried out by means of a pre-programmed logic provided by the designer. Depending upon the logic the decision may be to change one or more of the controllable process.

3. Modification function:-While the decision function is a logic function,

modification is concerned with a physical or mechanical change in the system. It is a hardware function rather than a software function. The modification involves changing the system parameters or variables so as to drive the process towards a more optimal state.

WHY ADAPTIVE??
NC systems: Experience and knowledge of part programmer Work piece and tool materials Tool conditions Radius of cutter Other parameters CNC systems: Increased production rates Increased tool life Greater part protection Less operator intervention Easier part programming Less time to generate part program

ADAPTIVE CONTROL SYSTEMS

TYPES: Adaptive control with optimization(ACO) Adaptive control with constraints(ACC) Geometric Adaptive control(GAC)

Adaptive control with optimization

In this system the performance is optimized according to the given performance index Index of performance Is usually a economic function I;e ,maximum production rate or minimum machining cost
Its a ratio of work material removal rate (MRR) to tool

wear rate (TWR)

Index of performance=

MRR TWR

Adaptive control with constraints

In this system the machining conditions such as

feed rate or speed are maximized within given limits of machine and tool constraints Adaptive controllers are fed by signals of following 3 sensors: TCM sensor(tool condition monitor eg camera) Tool vibration sensor(Accelerometer) Spindle torque sensor(Strain gauge)

Important constraints for ACC

Max or min spindle speed Max allowed torque Max or min allowed chip load Max permitted feed rate Max permitted impact chip load Max allowed vibration

Geometric Adaptive Control

Used in finish machining operations Cutting speed is taken constant, machining feed

is manipulated Sensors are mounted on the spindle to measure tool deflection, spindle motor current.

Advantages of ACC Increased production rates Increased tool life Greater part protection Less operator intervention Easier part programming Less time required for part program

L4

Difference B/w SPMM & NC M/c SPMM NC

y Fixed sequence of operation y Mass production of identical y y y Flexible sequence of y y y

y y

parts More set up time Program or sequence of operation is built into hard ware Less scope of variation as it is costly More floor area is required for tooling and work holding

y y

operation Short /Batch production of parts Less set up time Program or sequence of operation is made on computer then saved into hard ware More scope of variation Less floor area is required for tooling and work holding

Difference B/w NC & CNC M/c NC CNC

y First generation y Use punched cards/punched tapes etc y They work on offline mode y These are programmed in part y y y Advanced versions y Use a dedicated computer on which

programs y Difficult to program for complex parts y The program are difficult to understand y If a wrong code is punched ,then it can cause accident because the program can be checked only by actual shop floor run

y y y

instructions are typed directly They work on online mode These are programmed in later generation languages like APT ,ADAPT etc which use English statements Easy to program for complex parts The program are difficult to understand The programs can be checked in pre run state in simulation mode

Advantages of CNC over NC -Easier to program -More flexible -Reduced data reading error(data tape is read once only ,then data is stored in computer memory ) - Easy storage of existing programs and online editing possible -Easy to change a program -Conversion of units is possible in program -Can be easily integrated with DNC system - Avoids human errors - CNC machines are safer to operate - Complex geometry is produced as cheaply as simple ones - Usually generates closer tolerances than manual machines

Advantages of CNC SYSTEM:

High Repeatability and Precision e.g. Aircraft parts Volume of production is very high Complex contours/surfaces need to be machined. E.g. Turbines Flexibility in job change, automatic tool settings, less scrap More safe, higher productivity, better quality Less paper work, faster prototype production, reduction in lead times

Disadvantages:
Costly setup, skilled operators Computers, programming knowledge required Maintenance is difficult Maintenance is costly AC room and controlled environment

Advantages of DNC
y The computer can program many m/c s at a time . y Tape is prepared in m/c itself . y The tape can be read by m/c itself so tape reader is not

needed. y The main frame computer location can be remote