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Simulation based optimization for controller parameterization of machine tool axes – advanced application

Hipp K., Schöberlein C., Schlegel H., Neugebauer R.

Journal of Machine Engineering

2017

Vol. 17, No. 1

57--68

The quality of the controller parameterization of a drive system has direct influence on the obtained performance. Nevertheless, the commissioning is mainly done today by the application of basic tuning rules or not comprehensible automatisms. This often leads to not optimal performance. An alternative approach is to parameterize the typical controller cascade, which is widely used in standard industrial controllers, in one step by using the so-called “simulation-based optimization” (SBO). Significant advantages are the opportunity of defining specific restrictions concerning the desired controller parameterization and the possibility for directly processing non-linear systems without approximations. Furthermore, friction, additional filters in the cascade or controller structure extensions like the Advanced Position Control (APC) can be considered. Therefore, in the present paper, the application and the results of the SBO for different drive systems will be presented. After an introduction, the paper describes the basic principles of the simulation based optimization including the application for controller parameterization. Subsequently, the results for indirect velocity control of a test rig are discussed. After that, the findings for the commissioning of a direct position controller of an industrial servo press are presented. The paper closes with a summary and an outlook.

Combination of criteria for controller parameterisation in the time and frequency domain by simulation-based optimisation

Hipp K., Uhrig M., Hellmich A., Schlegel H., Neugebauer R.

Journal of Machine Engineering

2016

Vol. 16, No. 4

70--81

The position controller cascade is widely used in standard industrial controllers. Its controller parameterisation is commonly performed by either applying basic tuning rules or by carrying out not comprehensible design automatisms.In this paper an alternative approach to parameterise the cascade in one step is presented. It bases on established methods within the field of optimisation research specifically the so-called simulation-based optimisation (SBO), which can also handle non-linear models and various constrains. Own research showed, that criteria in the time domain as well as in the frequency domain are suitable optimisation criteria. However, both types have individual advantages and disadvantages. Therefore, in this research, selected representatives from both types were combined as new multi-objective optimisation criteria and investigated according to their performance. Investigations were performed for a test rig model (third order transfer function plus dead time and friction).The paper presents fundamentals of the SBO and a description of the optimisation criteria, obtained results as well as their verification on the test rig. Also, the derived controller parameterisations are compared to the integrated tuning automatism.