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2 Journal of Machine Engineering

2 2017

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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.

Joining by upset bulging – tooling design and new concepts for online process control using servo presses and local heating

Sviridov A., Grützner P., Rusch M., Bambach M.

Journal of Machine Engineering

2017

Vol. 17, No. 1

78--87

Conventional fusion-welding techniques pose limitations in modern multi-material assemblies due to the heat input. The negative influence of the heat-affected zone on the material properties must be avoided particularly in high-strength steels. During mechanical joining processes, which may also be used for joining of different materials e.g. steel and aluminium, high-performance joints can be produced without degradation of the material properties. Joining by upset bulging is an innovative joining method based on plastic buckling of tubes under axial compression. In previous investigations of joining by upset bulging the process parameters were determined and joints of tubes with sheet metal were tested under static and dynamic loads. The results of these studies have shown that the process of upset bulging has a large potential for the production of joints of tubes with sheets and plates. The present paper focuses on the tooling concepts for an efficient use of the technology and describes methods to control the forming and joining process. Two aspects are covered: (i) the application of servo-presses for joining by upset bulging and their possibilities for on-line process control, (ii) a moderate, process-integrated local heating of the forming area to avoid the formation of cracks and to further increase the strength of the joints.