Servo Controller Adaptive Parameter Tuning for Vibration Reduction
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Solution Overview
Problem
Existing servo controllers in machine tools face challenges in optimizing parameters such as gains and filter settings due to fixed conservative settings, leading to oscillations and vibrations during machining, which can result in reduced cycle times and surface scratches.
Innovation Solution
A servo controller that derives chronological or event-sequential data from operation plans to adaptively change parameters like velocity gain, position gain, feedforward gain, and acceleration/deceleration time constants, optimizing them based on predicted machine states to enhance machining accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conservative fixed parameters are used to reduce oscillation, then stability is improved, but cycle time increases and productivity decreases
Solution Approach 1:
The patent applies dynamics by transitioning from fixed conservative parameters to dynamically adjustable parameters. The controller automatically changes velocity gain, position gain, and filter frequency based on real-time machine state (idle, positioning, machining), allowing the system to adapt its stability characteristics to current operational requirements rather than maintaining fixed conservative settings throughout.
Solution Approach 2:
The patent implements parameter changes by systematically varying control parameters (velocity gain, position gain, filter frequency) according to the machine's operational state. During idle periods, higher gains are permitted to reduce cycle time, while during machining operations, parameters are adjusted to maintain stability and reduce vibration, thus resolving the contradiction between productivity and stability.
2Productivity
If optimal parameters are set for certain conditions, then productivity is improved, but vibration occurs when machine state changes
Solution Approach 1:
The patent employs feedback mechanisms by continuously monitoring the machine's operational state (idle, positioning, machining) and using this information to adjust control parameters. The controller receives feedback about the current operation state and automatically modifies velocity gain, position gain, and filter frequency accordingly, preventing vibration when machine state changes while maintaining optimal productivity for each specific state.
Solution Approach 2:
The patent applies preliminary action by pre-defining optimal parameter sets for different operational states (idle, positioning, machining) and automatically selecting the appropriate set before state transitions occur. This allows the system to be prepared with optimal parameters for upcoming operations, maintaining productivity while preventing vibration through proactive parameter adjustment rather than reactive correction.
3Device complexity
If fixed parameters are used, then device complexity is reduced, but adaptability to machine state changes deteriorates
Solution Approach 1:
The patent implements self-service by enabling the controller to automatically adjust its own parameters based on monitored machine state without requiring external intervention or complex manual configuration. The system serves itself by detecting operational conditions and autonomously selecting optimal parameter sets, thereby maintaining simple device architecture while achieving high adaptability to varying machine states.
Data Source
AI summary
An object is to provide a servo controller which constantly optimizes parameters according to the state of a machine. A servo controller for controlling an electric motor which drives the axis of an industrial machine includes: a state value derivation unit which derives, from an operation program and/or operation plan information of the industrial machine, the chronological or event-sequential data of the state value of the electric motor or a driven member that is operated with the electric motor; and a parameter change unit which changes at least one parameter of a velocity gain, a position gain, a feedforward gain, a filter frequency and an acceleration/deceleration time constant after interpolation based on the chronological or event-sequential data derived in the state value derivation unit either chronologically or event-sequentially.