Abstract
Ball-screw drive system is one of the popular systems applied in machine tools such as milling machine due to its capability in producing high speed and accurate positioning. However, the typical linear PID controller in such system was unable to cope with the unavoidable nonlinear disturbances such as the cutting forces during the milling operation. Such cutting forces are varied with respective to different setting of the milling parameters. This paper proposes a modified nonlinear PID that is able to adjust its gains automatically to suit various ranges of tracking errors caused by the cutting forces. The parameters of the nonlinear function applied for proportional, integral, and derivative gains in the proposed controller were tuned independently, which differ to typical nonlinear PID that used a common parameters of nonlinear function for all three gains. Three controllers, namely; PID, nonlinear PID, and modified nonlinear PID were designed and numerically validated using a ball-screw drive positioning system. Cutting forces generated from milling process with the spindle speed of 1000 rpm, 1500 rpm, and 2000 rpm were injected into the system as the disturbance forces. The tracking performances of the designed controllers were compared and analyzed in terms of tracking error reduction, and cutting force rejection through Fast Fourier Transform analysis. The simulation results showed that the proposed controller outperformed the PID controller in both tracking error reduction and cutting force rejection with an average improvement of 28.05% and 45.39% respectively, and produced at least 2 folds better results than NPID controller.
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Acknowledgement
The authors would like to acknowledge the Centre for Autonomous Systems and Robotics Research (CASRR), Faculty of Engineering and Technology, Tunku Abdul Rahman University College, for the financial and facilities support. The authors also would like to thank Universiti Teknikal Malaysia Melaka for the equipment provided.
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Chiew, T.H., Chow, W.K., Jamaludin, Z., Bani Hashim, A.Y., Abdullah, L., Rafan, N.A. (2022). Design and Analysis of Modified Nonlinear PID Controller for Disturbance Suppression in Machine Tools. In: Ali Mokhtar, M.N., Jamaludin, Z., Abdul Aziz, M.S., Maslan, M.N., Razak, J.A. (eds) Intelligent Manufacturing and Mechatronics. SympoSIMM 2021. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-16-8954-3_11
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DOI: https://doi.org/10.1007/978-981-16-8954-3_11
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