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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.
A simulation-based optimization approach to design of phase excitation tapers for linear phased antenna arrays is presented. The design optimization process is accelerated by means of Surrogate-Based Optimization (SBO); it uses a coarse-mesh surrogate of the array element for adjusting the array’s active reflection coefficient responses and a fast surrogate of the antenna array radiation pattern. The primary optimization objective is to minimize side-lobes in the principal plane of the radiation pattern while scanning the main beam. The optimization outcome is a set of element phase excitation tapers versus the scan angle. The design objectives are evaluated at the high fidelity level of description using simulations of the discrete electromagnetic model of the entire array so that the effects of element coupling and other possible interaction within the array structure are accounted for. At the same time, the optimization process is fast due to SBO. Performance and numerical cost of the approach are demonstrated by optimizing a 16-element linear array of microstrip antennas. Experimental verification has been carried out for a manufactured prototype of the optimized array. It demonstrates good agreement between the radiation patterns obtained from simulations and from physical measurements (the latter constructed through superposition of the measured element patterns).
The present paper discusses the influence of simulation model accuracy on the convergence of electromagnetic structure simulation-based optimization. Neither response surface approximation method nor the algorithm of moving window filtering, commonly used for simulation error compensation, is not fully capable of guaranteeing proper convergence. The non-expensive device model with coarse meshing and a modified error compensation method can yield satisfactory results in a reasonable time.
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