• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.781-784
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• 2005

The feed drive inclination significantly influences product quality, machine tool accuracy and life time. However, the accurate measurement of the inclination needs the skilled engineers and the accurate leveling instruments such as spirits or electric levels. In this study a novel methodology for the estimation of inclination angle of machine tool feed drive is proposed. The proposed methodology utilizes the motor current signals and a new mathematical model of machine tool feed drive considering inclination. The experiment results showed that the proposed method successfully estimates the inclination angle, as well as newly proposed model also enhances the accuracy of the machine tool feed drive model by introducing the inclination effects.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.5
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• pp.447-454
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• 2015

Design and application of hardware-in-the-loop simulation (HILS) for design of CNC-controlled machine tool feed drives is discussed. The CNC machine tool is a complex mechatronics system where the complexity results from the software-based controller composed of a variety of functionalities and advanced control algorithms. Therefore, using a real CNC controller in the control simulation has merits considering the efforts and accuracy of the simulation modeling. In this paper challenges in HILS for a CNC controlled feed drive, such as minimization of time delay and transmission error that are caused by discretization of the feed drive model, is elaborated. Using an experimental HILS setup of a machine tool feed drive applications in controller gain selection and CNC diagnostics are presented.

• Journal of Power Electronics
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• v.4 no.4
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• pp.217-227
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• 2004

A robust controller that combines the merits of the feed-back, feed-forward and model-following control for induction motor drives utilizing field orientation control is designed in this paper. The proposed controller is a two-degrees-of­freedom (2DOF) integral plus proportional & rate feedback (I-PD) speed controller combined with a model-following (2DOF I-PD MFC) speed controller. A systematic mathematical procedure is derived to find the parameters of the 2DOF I-PD MFC speed controller according to certain specifications for the drive system. Initially, we start with the I-PD feed­back controller design, then we add the feed-forward controller. These two controllers combine to form the 2DOF I-PD speed controller. To realize high dynamic performance for disturbance rejection and set point tracking characterisitics, a MFC controller is designed and added to the 2DOF I-PD controller. This combination is called a 2DOF I-PD MFC speed controller. We then study the effect of the 2DOF I-PD MFC speed controller on the performance of the drive system under different operating conditions. A computer simulation is also run to demonstrate the effectiveness of the proposed controller. The results verify that the proposed 2DOF I-PD MFC controller is more accurate and more reliable in the presence of load disturbance and motor parameter variations than a 2DOF I-PD controller without a MFC. Also, the proposed controller grants rapid and accurate responses to the reference model, regardless of whether a load disturbance is imposed or the induction machine parameters vary.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.77-78
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• 2012

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.2
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• pp.88-93
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• 2017

Due to the requirement of the development of the precision manufacturing industry, the accuracy of machine tools has become a key issue in this field. A critical factor that affects the accuracy of machine tools is the feed system, which is generally driven by a ball screw. Basically, to improve the performance of the feed drive system, which will be thermally extended lengthwise by continuous usage, a thermal error compensation system that is highly dependent on the feedback temperature or positioning data is employed in the machine tool system. Due to the overdependence on measuring technology, the cost of the compensation system and low productivity level are inevitable problems in the machine tool industry. This paper presents a novel feed drive thermal error compensation system method that could compensate for thermal error without positioning or temperature feedback. Regarding this thermal error compensation system, the heat generation of components, principal of compensation, thermal model, mathematic model, and calculation method are discussed. As a result, the test data confirm the correctness of the developed feed drive thermal error compensation system very well.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2005.05a
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• pp.97-102
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• 2005

This paper presents feed rate optimizaton of a PMLSM driven feed-slide for mininum vibrations by smoothing velocity curve with finite jerk. First of all, the PMLSM was designed and made to reduce detent force. Next, a PMLSM driven feed-slide system was mathematically modeled as a 4-degree-of-freedom lumped parameter model. The key idea of our vibration minimization method is to find out the most appropriate smooth velocity curve with finite jerk. The validity of our proposed method has been verified by comparing computer simulation results of the feed-slide model with experimental ones.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.2
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• pp.71-76
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• 2003

A virtual machine tool (VMT) is presented in this two-part paper. In Part 1, the analytical foundation for a virtual machining system is developed, which is envisioned as the foundation for a comprehensive simulation environment capable of predicting the outcome of cutting processes. The VHT system undergoes "pseudo-real machining", before actual cutting with a CNC machine tool takes place, to provide the proper cutting conditions for process planners and to compensate or control the machining process in terms of the productivity and attributes of the products. The attributes can be characterized by the machined surface error, dimensional accuracy, roughness, integrity, and so forth. The main components of the VMT are the cutting process, application, thermal behavior, and feed drive modules. In Part 1, the cutting process module is presented. When verified experimentally, the proposed models gave significantly better prediction results than any other methods. In Part 2 of this paper, the thermal behavior and feed drive modules are developed, and the models are integrated into a comprehensive software environment.vironment.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.11
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• pp.74-79
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• 2001

In this two-part paper, a virtual machine tool (VMT) is presented. In part 1, the analytical foundation of a virtual machining system, envisioned as the foundation for a comprehensive simulation environment capable of predicting the outcome of cutting processes, is developed. The VMT system purposes to experience the pseudo-real machining before real cutting with a CNC machine tool, to provide the proper cutting conditions for process planners, and to compensate or control the machining process in terms of the productivity and attributes of products. The attributes can be characterized with the machined surface error, dimensional accuracy, roughness, integrity and so forth. The main components of the VMT are cutting process, application, thermal behavior and feed drive modules. In part 1, the cutting process module is presented. The proposed models were verified experimentally and gave significantly better prediction results than any other method. The thermal behavior and feed drive modules are developed in part 2 paper. The developed models are integrated as a comprehensive software environment in part 2 paper.

• Journal of Power Electronics
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• v.7 no.2
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• pp.159-173
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• 2007

In this paper, an intelligent sliding-mode position controller (ISMC) for achieving favorable decoupling control and high precision position tracking performance of permanent-magnet synchronous motor (PMSM) servo drives is proposed. The intelligent position controller consists of a sliding-mode position controller (SMC) in the position feed-back loop in addition to an on-line trained fuzzy-neural-network model-following controller (FNNMFC) in the feedforward loop. The intelligent position controller combines the merits of the SMC with robust characteristics and the FNNMFC with on-line learning ability for periodic command tracking of a PMSM servo drive. The theoretical analyses of the sliding-mode position controller are described with a second order switching surface (PID) which is insensitive to parameter uncertainties and external load disturbances. To realize high dynamic performance in disturbance rejection and tracking characteristics, an on-line trained FNNMFC is proposed. The connective weights and membership functions of the FNNMFC are trained on-line according to the model-following error between the outputs of the reference model and the PMSM servo drive system. The FNNMFC generates an adaptive control signal which is added to the SMC output to attain robust model-following characteristics under different operating conditions regardless of parameter uncertainties and load disturbances. A computer simulation is developed to demonstrate the effectiveness of the proposed intelligent sliding mode position controller. The results confirm that the proposed ISMC grants robust performance and precise response to the reference model regardless of load disturbances and PMSM parameter uncertainties.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.1
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• pp.40-47
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• 2004

This paper proposes a three-axis coupling controller designed to improve the contouring accuracy in machining of 3D nonlinear contours. The proposed coupling controller is based on an innovative 3D contour error model and a PID control law. The novel contour error model provides almost exact calculation of contour errors in real-time for arbitrary contours and can be integrated with any type of existing interpolator. In the proposed method, three axes of motion are coordinated by the proposed coupling controller along with a proportional controller for each axis. The proposed contour error model and coupling controller are evaluated through computer simulations. The simulation results show that the proposed 3-axis coupling controller with the new contour error model substantially can improve the contouring accuracy by order of magnitude compared with the existing uncoupled controllers in high-speed machining of nonlinear contours.