Numerical Controller Dynamic Gain Switching for Synchronization
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Solution Overview
Problem
Existing numerical controllers for machine tools face challenges in accurately synchronizing the position of a slave axis with a master axis, particularly due to synchronization errors caused by changes in master axis speed and vibrations, which affect synchronization performance and lead to increased errors.
Innovation Solution
A numerical controller that dynamically switches the position control gain during synchronous control based on predetermined physical quantities such as synchronization error, external signals, or servo delay, adjusting the compensation value to improve tracking performance and reduce synchronization errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the position control gain is low, then the expectation time is long, but the difference between expected position and synchronous position increases, resulting in higher synchronization error
Solution Approach 1:
The patent applies dynamics by making the position control gain variable rather than constant. The gain is dynamically adjusted based on the master axis speed: when speed changes occur, the gain is reduced to extend expectation time and reduce synchronization error; when speed is constant, the gain is increased to shorten expectation time and improve response. This dynamic adjustment resolves the contradiction between expectation time and synchronization accuracy.
Solution Approach 2:
The patent changes the parameter of position control gain based on operating conditions. By detecting master axis speed changes and adjusting the gain parameter accordingly, the system adapts to different operational states. This parameter change allows the system to optimize both expectation time and synchronization accuracy under varying speed conditions.
2Speed
If the position control gain is high, then the synchronization performance is affected by vibration, but the response to speed changes is improved
Solution Approach 1:
The system dynamically adjusts the position control gain based on detected vibration conditions. When vibration is detected during constant speed operation, the gain is reduced to improve stability and reduce synchronization error. During speed changes, the gain is increased to improve response. This dynamic adaptation resolves the contradiction between response speed and stability.
Solution Approach 2:
The patent changes the position control gain parameter according to operational conditions including vibration detection. By monitoring the operational state and adjusting the gain parameter accordingly, the system achieves optimal performance for both speed response and vibration resistance in different operating phases.
3Device complexity
If a constant position control gain is used during synchronization, then the control system is simple, but synchronization error occurs during master axis speed changes or vibration
Solution Approach 1:
The patent implements dynamic gain adjustment by introducing speed detection and gain switching logic. The system detects master axis speed changes and vibration conditions, then switches between different gain values. This dynamic approach maintains relatively simple control architecture while significantly improving synchronization accuracy under varying operating conditions.
Data Source
AI summary
A numerical controller outputs a position command corresponding to a synchronous position in consideration of a servo delay of a slave axis, to the slave axis from a real position of a master axis, in order to perform position control of the slave axis, thereby making a real position of the slave axis synchronously follow the real position of the master axis. A position control gain of the slave axis is changed based on a predetermined physical quantity during the synchronous control and a compensation value for the position command for the slave axis is varied depending on the amount of change of the position control gain of the slave axis.