Real-time Contour Error Estimation Research Articles

Cross-coupled control based on real-time Double Circle contour error estimation for biaxial motion system

In contour machining, contour error is a major factor affecting machining quality. In order to improve the performance of contour following, many control techniques based on real-time contour error estimation have been developed. In this paper, a Double Circle contour error estimation method is proposed. First, based on the kinematic information of the reference point on the command trajectory, five interpolation points closest to the actual point are obtained. Then the approximate contour error is obtained by employing the Double Circle approximation method. Compared with the common contour error approximation methods, the proposed method can achieve high precision approximation. In addition, according to the proposed contour error approximation method, the cross-coupled control strategy is improved. Experiments prove the effectiveness of the proposed estimation method and control strategy.

The model-free adaptive cross-coupled control for two-dimensional linear motor

In order to improve the contour error accuracy of two-dimensional linear motor, an improved cross-coupled control (CCC) scheme combining real-time contour error estimation and model-free adaptive control (MFAC) is proposed. The real-time contour error estimation method is based on CCC theory and coordinate transformation idea. It can accurately determine the contour error point of regular contour and avoid the influence of tracking error on the contour error. At the same time, for the design of two-axis error controller, only the input and output data generated by two-dimensional linear motor in reciprocating motion are used to design a multiple input multiple output-model-free adaptive control (MIMO-MFAC) algorithm, this algorithm avoids the dependence on accurate mathematical model and reduces the control difficulty. The experimental comparison showed that the proposed method improves the system tracking accuracy and contour accuracy, and verifies the proposed method correctness and effectiveness.

Real-Time Contour-Error Estimation Methods for Three-Dimensional Free-Form Parametric Curves in Contour-Following Tasks

It is crucial to control the contour error in curved contour-following tasks caused by reasons such as servo delay and external disturbance. Contour-error estimation plays as a precondition for its further control. Existing methods can hardly keep well estimation accuracy for high-speed following of free-form curves with sharp corners, especially for three-dimensional curves. Consequently, this paper presents three high-precision real-time contour-error estimation methods for spatial free-form parametric curved contour following. By generating and updating the backstepping point according to the tangential tracking error, a multiple tangential approximation method is presented first. Then, a spatial circular approximation method is given by means of approximating the actual-position nearby region of the desired contour with a spatial circle. Finally, via modification of the Newton method so as to improve its stability without sacrificing of its fast convergence property, an initial value regeneration-based Newton algorithm is proposed for contour-error estimation. All of the presented methods take both estimation precision and calculation burden into consideration, and possess their own advantages. Using these algorithms, the contour error can be rapidly estimated in vector form with a high accuracy. Simulation and experimental results demonstrate the feasibility and the superiority of the presented algorithms.

Real time parameter based contour error estimation algorithms for free form contour following

The contour following task of a multi-axis servo system is one of the most important applications of modern Computer Numerical Control (CNC) machine tools, and is widely seen in many types of CNC machining. Hence, the reduction of contour error occurring in the contour following process is paramount and deserves more comprehensive investigation. In general, the calculation of precise contour error in real time is very challenging if not impossible, in free-form curve following tasks. To deal with such a problem, this paper proposes six real-time contour error estimation methods for free-form parametric curves. The feasibility of these methods is verified with several NURBS parametric curve contour following experiments. In addition, experimental results reveal that the proposed methods can provide more accurate contour error estimation for various free-form curves than the other estimation algorithms tested in the experiments. With the proposed contour error estimation approach, advanced motion control schemes can be designed to efficiently reduce contour errors of contour following tasks.

Iterative Learning Cross-Coupled Control for XY Table Based on Real-Time Contour Error Estimation

The contour accuracy of XY table directly driven by two linear motors was influenced by the complicated reel-time contour error model of free-form curves, uncertainty external disturbance and dynamic matching between X axis and Y axis. To establish XY table model that easily calculated and suitable for free-form curves, real-time contour error estimate method was adopted. In order to reduce uncertainty external disturbance and dynamic matching between X axis and Y axis, the iterative learning cross-coupled controller (ILCCC) was designed for current compensation on X axis and Y axis. Simulation results show that the control scheme can enhance the robustness of the system, and effectively improve the XY table of contour precision.

Performance analysis of cross-coupled controllers for CNC machines based upon precise real-time contour error measurement

Experimental results from the implementation of a cross-coupled control scheme on a 3-axis CNC mill governed by an open-architecture software controller are presented. Unlike prior cross-coupling schemes, which depend on osculating-circle approximations to the commanded toolpath for real-time contour error estimation, the proposed scheme is based on essentially exact contour error computations for free-form curved paths. The implementation illustrates the feasibility of precise real-time contour error computation with a modest (300 MHz) CPU and a 1024 Hz sampling frequency. For a P-type controller and paths with strong curvature variation, the new scheme ensures much better diminution of contour error than earlier methods. The contour error is observed to decrease monotonically as the relative gain is increased, up to a critical gain value that incurs instability. For PI-type controllers, the comparative contour error reduction is more modest, due to their effective suppression of steady-state position error along the path. In practice, the exact contour error measure permits accurate tracking of strongly curved paths using a simple P-type controller, with smaller feedrate fluctuations than a PI-type controller incurs.

Motion Controller Design for Contour-Following Tasks Based on Real-Time Contour Error Estimation

Reduction of contour error is an important issue in contour-following applications. One of the common approaches to this problem is to design a controller based on contour error information. However, for the free-form contour-following tasks, there is a lack of effective algorithms for calculating contour errors in real time. To deal with this problem, this paper proposes a real-time contour error estimation algorithm. In addition, a motion control scheme that combines a position loop controller (which utilizes a velocity command feedforward) with a tangential-contouring controller (TCC) is employed to improve the contour-following accuracy. When implementing the TCC, a coordinate transformation matrix is needed. Unfortunately, it is difficult to calculate the coordinate transformation matrix when performing the free-form contour-following task. To overcome this difficulty and facilitate the use of contour controllers, a systematic approach is employed to derive the coordinate transformation matrix for the free-form contour-following tasks. Experimental results demonstrate the effectiveness of the proposed contour error estimation algorithm and the motion control scheme