• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.1-6
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• 2015

Tool condition monitoring plays one of the most important roles in the improvement of both machining quality and productivity. In this regard, various process signals and monitoring methods have been developed. However, most of the existing studies used cutting force or acoustic emission signals, which posed risks of interference with the machining system in dynamics, fixturing, and machining configuration. In this study, a feed motor current signal is used as a process signal representing process and tool states in tool breakage monitoring based on an adaptive autoregressive model and unsupervised neural network. From the experimental results using various cases of tool breakage, it is shown that the developed system can successfully detect tool breakage before two revolutions of the spindle after tool breakage.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.9
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• pp.31-37
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• 1996

This Paper is concerned with effective signal identification method for tool breakage and micro chipping using discrete wavelet transform of feed motor current in milling operations. The wavelet transform uses an analyzing waveletfunction which is localized in both frequency and time domain to detect subtle time localized changes in input signals. The changing pattern of wavelet coefficient is continuously compared to detect tool breakage and micro chipping over one spindle revolution. The results indicate that the wavelet transform can identify tool failure with much greater sensi- tivity than the time domain monitoring and frequency domain monitoring such as FFT. Experimental results are presented to support the proposed scheme.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.5
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• pp.110-119
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• 1998

Dynamic cutting force variations in milling process were measured indirectly using spindle motor current. Magnitude of the spindle motor current is independent of cutting direction. Quasi-static sensitivity of the spindle motor current is higher than that of the feed motor current. Dynamic sensitivity of the spindle motor current is lower but cutting force was correctly represented by spindle RMS current in rough milling. In rough milling, chipping and tool fracture were well detected by the proposed tool fracture index using spindle motor current.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.10
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• pp.15-27
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• 1997

Quasti-static cutting force variations in milling process are measured indirectly using spindle motor current. Quasi-static sensitivity of the spindle motor current is higher than that of the feed motor current. Magnitude of the spindle motor current is independent of cutting direction. The linear relationship between the cutting force and the spimdle motor RMS current at various spindle rotational speed is obtained. Frequency/ Voltage(F/V) converter voltage is measured to identify the spindle speed and to determine the cutting force at various spindle speeds. Overload on the tool during milling process can be detected using the proposed indirect cutting force measurement. Based on these measurements, cutting force is regulated at a constant level by feedrate control.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.1
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• pp.156-161
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• 1992

In this research a monitoring system for turning using NC information and the current of feed motor as a monitoring signal was developed. The overall system consists of modules such as learning process, NC data transmission, generation of forecast information, signal acquisition, monitoring and post process. In the learning process, the reference data and the cutting force equation necessary for monitoring are obtained from the accumulated monitoring results. In the generation of forecast information, the information of forecasted cutting forces is acquired from the cutting force equation and NC program and appended to each NC block as a monitor code. Reliability of monitoring is improved by using the monitor code in the real-time monitoring. Monitoring module is divided into two parts : the off-line monitoring where errors of NC program are checked and the on-line monitoring where the level of motor current is monitored during cutting operations. If the actual current level exceeds the limit value provided by the monitor code in the level monitoring, it is recognized as abnormal. In the event of abnormal status, the post processor sends the emergency stop signal to NC controller to stop the operation. Actual experiments have shown that the developed monitoring system works well.

• Journal of Power Electronics
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• v.16 no.3
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• pp.994-1003
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• 2016

Two major obstacles in the utilization of electrical vehicles are their price and range. The collaboration of direct torque control (DTC) with induction motor (IM) is preferred for its low cost, easy implementation, and parameter independency. However, in terms of edges, the method has drawbacks, such as variable switching frequency and undesired current harmonic distortion. These drawbacks result in acoustic noise, reduced efficiency, and electromagnetic interference. A feed-forward approach for stator-flux-oriented DTC with space vector pulse-width modulation is presented in in this paper. The outcome of the proposed method is low current harmonic distortion with fixed switching frequency while preserving the torque performance and simple application feature of basic DTC. The method is applicable to existing and forthcoming IM drive systems via software adaptation. The validity of the proposed method is confirmed by simulation and experimental results.

• The Transactions of The Korean Institute of Electrical Engineers
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• v.60 no.5
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• pp.1011-1016
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• 2011

This paper presents a robust current controller for a surface-mounted permanent magnet synchronous motor(SPMSM) by using a PI observer. The decoupling PI(proportional-integral) controller combined with an additional feed-forward compensation has been used for the current controller. The classical feed-forward compensation using velocity information and system parameters is not expected to achieve a robust performance against parameter uncertainties. This paper has adopted a PI observer for the feed-forward compensation to cope with parameter uncertainties without using velocity information. A simple PI observer has been designed to compensate the disturbances that represent velocity coupled terms and parameter uncertainties. Experimental results as well as computer simulations with 630W SPMSM confirm that the proposed approach can deal with the effects of the disturbance and improve the control performance.

• Proceedings of the KIEE Conference
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• 2007.10a
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• pp.67-69
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• 2007

PMSM (Permanent Magnet Synchronous Motor) current control is a most inner loop of electromechanical driving systems and it plays a foundation role in the hierarchy's control loop of several mechanical machine systems. In this paper, a simple RMRAC control scheme for the PMSM is proposed in the synchronous frame. In the synchronous current model, the input signal is composed of as a calculated voltage by adaptive laws and system disturbances. The gains of feed-forward and feed-back controller are estimated by the proposed e-modification methods respectively, where the disturbances are assumed as filtered current tracking errors. After the estimation of the disturbances from the tracking errors, the corresponding voltage is fed forward to control input to compensate for the disturbances. The proposed method is robust to high frequency disturbances and has a fast dynamic response to time varying reference current trajectory. It also shows a good real-time performance duo to it's simplicity of control structure. Through the simulations considering several cases of external disturbances and experimental results, efficiency of the proposed method is verified

• Proceedings of the KIPE Conference
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• 1999.07a
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• pp.563-568
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• 1999

Generally the control method of wire feeding motor in welding machine has been used full-wave phase control method. The fire-angle control generates low frequency speed ripple, and it causes the output current ripple. So it results in the variation of welding condition and low welding performances such as spatter generation and bead state. For the purpose of welding performances improvement by speed controller in wire feeding motor, in this paper the constant speed control method for welding machine is proposed. The proposed system is composed of speed control loop and current control loop. As a result of experiment by using proposed constant wire feed experiment by using proposed constant wire feed speed controller, the output voltage and current waveform and metal transfer are maintained stably. And moreover the number of instantaneous short circuit occurrence is reduced remarkably.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.653-657
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• 1996

This paper presents adaptive cutting force control in milling process using indirect cutting force measurement. The cutting forces in X, Y, and Z axes are measured indirectly from the sensing current of the feed-drive servo motor. After modelling the feed-drive system of a horizontal machining center, the relation between the cutting force and the servo motor current is analyzed. The pulsating milling forces are measured from the sensing current within the bandwidth of the servo. It is shown that indirect cutting farce measurement can be used in adaptive cutting force control. The adaptive control scheme which is globally convergent and stable is attached to a commercial CNC machining center. Cutting experiments on end milling are performed for diagonal cutting.