Abstract
This paper proposes an innovative mechatronic piezo-actuated module to control vibrations in modern machine tools. Vibrations represent one of the main issues that seriously compromise the quality of the workpiece. The active vibration control (AVC) device is composed of a host part integrated with sensors and actuators synchronized by a regulator; it is able to make a self-assessment and adjust to alterations in the environment. In particular, an innovative smart actuator has been designed and developed to satisfy machining requirements during active vibration control. This study presents the mechatronic model based on the kinematic and dynamic analysis of the AVC device. To ensure a real time performance, a H2-LQG controller has been developed and validated by simulations involving a machine tool, PZT actuator and controller models. The Hardware in the Loop (HIL) architecture is adopted to control and attenuate the vibrations. A set of experimental tests has been performed to validate the AVC module on a commercial machine tool. The feasibility of the real time vibration damping is demonstrated and the simulation accuracy is evaluated.
Highlights
In modern machine tools, mechatronics may play a key role in improving machining performance and guaranteeing high quality and efficiency
The active vibration control (AVC) device is composed of a host part integrated with sensors and actuators synchronized by a regulator; it is able to make a self-assessment and adjust to alterations in the environment
This study aims at dealing with control and mitigation of vibrations in machining by proposing an innovative mechatronic device based on piezoelectric stack actuators
Summary
Mechatronics may play a key role in improving machining performance and guaranteeing high quality and efficiency. An active module is presented, composed of a host part integrated with sensors and actuators synchronized by a regulator able to make a self-assessment and adjust to the alterations in the environmental In this way, mechanical dynamics and the control theories have been examined in designing smart piezoelectric structures. Vibrations represent one of the main issues that affect the quality of a workpiece, and they need to be considered from the design phase of a machine tool. They are usually classified in three main categories: free, self-induced, and forced vibrations. The second class of vibrations, known as chatter as well, is produced during the cutting process itself and they are induced by Sensors 2016, 16, 1577; doi:10.3390/s16101577 www.mdpi.com/journal/sensors
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